Greenlee 854 User manual

SERVICE MANUAL
854
Quad Bender
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
Serial Number AKM

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
Purpose
This manual is intended to familiarize authorized
Greenlee service center personnel with the safe
operation and maintenance procedures for the
Greenlee 854 Quad Bender, beginning with Serial
Number AKM.
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge at www.greenlee.com.
The Greenlee 854 Quad Bender is protected by
U.S. Patent No. 5,226,305.
Other Publications
Instruction Manual: Publication 52033653
All specications 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.
Molex is a registered trademark of Molex Inc.
KEEP THIS MANUAL
Table of Contents
Safety ............................................................................ 2
Purpose ......................................................................... 2
Other Publications......................................................... 2
Important Safety Information .....................................3–4
Transportation and Setup.............................................. 5
Maintenance...............................................................6–9
Troubleshooting......................................................10–11
Exploded Views and Parts Lists.............................12–19
Wiring Diagram.......................................................20–21
I/O Electrical Schematic .........................................22–23
PCB Layout ................................................................. 24
Power Generation Unit ...........................................25–27

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury or death.
Do not use this tool in a hazard-
ous environment. Hazards include
ammable liquids, gases, or other
materials. Using this tool in a hazard-
ous environment can result in a re
or explosion.
Failure to observe this warning will
result in severe injury or death.
Electric shock hazard:
Connect the power cord to a
120 volt, 20 amp receptacle on a
ground fault protected circuit only.
See Grounding Instructions.
Do not modify the power cord or
plug.
Inspect the power cord before
use. Repair or replace the cord if
damaged.
Disconnect the unit from power
before servicing.
Failure to observe these warnings
could result in severe injury or death.
•
•
•
•
Do not expose to rain.
Do not use in wet or damp
locations.
Failure to observe these warnings
could result in severe injury or death.
•
•
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
Do not remove guards.
Failure to observe this warning could
result in severe injury or death.

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
IMPORTANT SAFETY INFORMATION
Extension cords:
Use only three-wire, 12-gauge
extension cords that have three-
prong grounding-type plugs and
three-hole receptacles that accept
the tool’s plug.
Do not use extension cords that
are longer than 30 m (100').
Repair or replace damaged
extension cords.
Failure to observe these warnings
could result in severe injury or death.
•
•
•
Pinch points:
Keep hands away from bending
shoe, rollers and conduit when
bender is in use.
Failure to observe this warning could
result in severe injury or death.
Adjust fork spacing to match fork tubes on bender.
Ensure caster brakes are locked and casters are
straight before inserting forks into fork tubes.
Forks must extend beyond ends of fork tubes a
minimum of 8".
Failure to observe this warning could result in severe
injury or death.
Unplug the bender before changing accessories.
Accidental startup could result in serious injury.
Conduit moves rapidly as it is bent. The path of
the conduit must be clear of obstructions. Be sure
clearance is adequate before starting the bend.
Do not operate the bender while wearing loose
clothing. 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.
Some bender parts and accessories are heavy
and may require more than one person to lift and
assemble.
Use only accessories and attachments recom-
mended by Greenlee.
Do not stand on the bender; the bender may tip
over.
Do not leave the tool running unattended. Do not
leave the tool until it comes to a complete stop.
Turn the power off and unplug the tool after use.
Ensure that all bystanders are away from the work
area when operating the bender.
Ensure that the work area is clean, dry, uncluttered,
and well-lit.
Use this tool for the manufacturer’s intended
purpose only. Use other than that which is
described in this manual can result in injury or
property damage.
Failure to observe these precautions may result in
injury or property damage.
•
•
•
•
•
•
•
•
•
•

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Transportation and Setup
Hoisting the Bender
To hoist the bender, use either slings (nylon or polyester)
or chains with hooks. Each side of the sling or chain
must be at least 915 mm (36") long to prevent contact
with the bender. All lifting components must be rated for
231 kg (510 lb).
1. Pivot the bending head to the horizontal position
with the 1-1/2" to 2" shoe upward (see Pivoting the
Bender Head in this section of the manual).
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.
Pivoting the Bender Head
The bender head has two bending positions — vertical
and horizontal. To change the bender head position:
1. Pull out the bender head pivot lock knob. It may be
necessary to twist the knob clockwise until the pin
clears the frame.
2. Pivot the bending head to the desired bending
position.
3. Push the bender head pivot lock knob back into
position so that the pin is fully engaged in the hole.
4. Twist the pivot lock knob counterclockwise until you
feel some resistance. Do not tighten it.

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Maintenance
Electric shock hazard:
Disconnect the unit from power
before servicing.
Failure to observe this warning could
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
Schedule
Component Maintenance
Activity
Maintenance
Interval
Chain Lubrication and
Tension Adjustement Every 6 months*
Roller
Supports
Cleaning and
Lubrication Every 6 months*
Commutator
Brushes
Replacement
When drive unit
performance
diminishes noticeably
* More often if the bender is used in dusty or corrosive environments.
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" to 2" shoe (see Changing Shoes in this
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 pressing
UNLOAD. Lubricate the entire length of the chain.
5. Check the amount of slack halfway between the
sprockets. If the chain slack is :
More than 25 mm (1"), proceed to step 6.
Less than 25 mm (1"), proceed to step 10.
6. Remove 11 screws (23) and motor guard (5).
7. Loosen the two motor mounting screws (25) on the
front, and the two on the back, and the nut (22).
8. Torque the eccentric locator (21) to 81 Nm (60 ft-lb).
Maintain this amount of torque while tightening the
nut (22) and two front screws (25).
9. Tighten the two rear screws (25).
10. Assemble in reverse order.
1/2" to 1-1/4" Roller Support
1. Disconnect the bender from the power source.
2. Remove support pivot pin (19). Remove roller
support (7).
3. Spray a motorcycle chain lubricant through the
3 mm (1/8") diameter hole in each roller. Rotate
each roller to distribute the lubricant.
4. Spray the pivot pin.
5. Wipe away any excess lubricant.
6. Replace the roller support and pivot pin.
•
•

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Maintenance (cont’d)
1-1/2" to 2" Roller Support
1. Disconnect the bender from the power source.
2. Remove the 1-1/2" to 2" shoe (see Changing Shoes
in this section of the manual).
3. See the 1-1/2" to 2" Roller Support Unit Exploded
View. Use a pair of needlenose pliers to disconnect
the springs (104) from the holes in the side of the
bender frame beneath the roller support unit.
4. See the Main Exploded View. Remove the squeeze
adjustment arm screw (97) and arm (74).
5. Remove the three button head cap screws (96) and
adapter sleeve (92).
6. Place one hand under the support arms (71) to
support the weight of the roller support unit.
Remove the eccentric shaft (91).
Note: You may need to rotate the eccentric shaft to
remove it.
Pinch points:
Use both hands to hold the two lead
and two tail rollers to prevent the
rollers from pivoting.
Failure to observe this precaution
may result in injury or property
damage.
7. Lift the roller support subassembly to the left and
upward.
8. On the 1-1/2" roller group:
Loosen the sleeve set screw (98) and remove the
1-1/2" pivot roller shaft (86) with grip (90). Remove
the sleeve (87).
Remove two hex head screws (93). Remove the
outer roller plate (75).
Remove the tail roller (84).
Remove all components of the split roller
assembly.
9. On the 2" roller group:
Loosen the sleeve set screw (98) and press out
the 2" pivot shaft (88). Remove the sleeve (89).
Remove the hex head screw (93). Remove one
retaining ring (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.
•
•
•
•
•
•
•
•
10. Clean off all of the grease and dirt.
11. Inspect each item. Replace any worn, damaged, or
missing items.
12. Lubricate all working surfaces with a high-quality
grease.
13. Replace all components in reverse order, noting the
following:
On both roller groups: To ease the assembly of
the split roller subassemblies, begin by slipping
the O-rings onto the side plates. Assemble the
split roller subassemblies as shown, then slip the
O-rings into their correct positions.
On the 2" roller group only: After replacing any
split roller components, add or remove shim
washers (99, 119, or 150) as needed.
On the 1-1/2" roller group: Install the two
Belleville washers (100) so that the inside diam-
eters contact each other.
Use Loctite®271 on the two hex head screws
(93). Torque to 55 to 61 Nm (40 to 45 ft-lb).
14. Position the roller support arms (71) as shown.
Assemble the roller groups to the support arms.
15. Reinstall the roller support unit to the bender. Keep
one hand under the support arms so they do not
drop completely below the set screw (107).
16. Insert the eccentric shaft (91).
Note: You may need to rotate the eccentric shaft to
get it to seat completely.
17. Install the adapter sleeve (92) and three button head
cap screws (96).
18. Install the adjustment arm (74) and adjustment arm
screw (97).
19. Attach the springs (104) to the holes in the side of
the bender frame beneath the roller support unit.
20. Put the bender in the horizontal bending position.
Adjust the set screw (107), if necessary, so that the
support arms (71) are centered between the front
and back plates. Engage and disengage the roller
support unit to be sure that it moves freely.
•
•
•
•

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Maintenance (cont’d)
Changing Shoes
1. Disconnect the bender from the power source.
2. Lock the bender head in the vertical bending
position (see Pivoting the Bender Head in the
Transportation and Setup section of this manual).
3. See the 1/2" to 1-1/4" Side Exploded View or the
1-1/2" to 2" Side Exploded View. Use heavy-duty
retaining ring pliers to remove the retaining ring (26)
that secures the shoe.
4. Remove the shoe from the spindle.
Drive lugs must
engage in
these holes.
5. Mount the replacement shoe onto the spindle. Align
the slot in 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.
Setting Roller Support Limit Switch
The switch is activated by the main outer roller support
arm, in the retracted position. Retract the switch from
the maximum switch travel by pivoting the switch in
its mounting holes and rotating it clockwise in its
mounting slot.
Set the squeeze adjustment at the maximum clockwise
position. Move the switch in a counterclockwise direc-
tion (with a 0.030" feeler gage between the roller arm
and the body). When the roller, arm, gage, and switch
body are in contact, tighten the mounting screws.
The switch lockout circuit is normally closed. Attach
alligator clips to the common and normally closed
switch terminals to check switch trip operation.
Do not insert meter probes into the Molex®plug.

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Maintenance (cont’d)
Setting Angular Position Limit Switch
Set 105° stop switch for maximum 1-1/2" to 2" shoe
rotation.
Rotate 1-1/2" to 2" shoe in the bend direction until the
pointer is at 105°.
Max. Bend Angle
Reduced
Bend Angle
Switch
Retaining
Screws
Loosen the socket head cap screws. Move the switch
to the maximum bend angle position, and then move
the switch in the reduced bend angle direction until the
switch is activated and continuity exists at the normally
open connections. Tighten the two mounting screws to
retain the switch.
Note: The lower switch mounting slots are not used.
Pointer Accuracy
Note: Pointers may be adjusted with shoes on the
spindle.
1. Loosen the two locking screws (29).
2. Move the pointer (30 or 31).
3. Tighten the screws.
Locking Screws
Commutator Brushes
1. Disconnect the bender from the power source.
2. See the Main Exploded View. Remove the 11
screws (23) and the motor guard (5). Remove the
motor guard.
3. Remove the power cord strain relief (37).
4. Refer to Drive Unit Exploded View. Remove the two
Allen screws and nuts that secure the shroud (6) to
the motor. Remove the shroud.
5. Push in the commutator brush retainer and move it
toward the brush (1) to release it. Unplug the brush
and remove it. Replace the brush if it is less than
6 mm (1/4") long.
6. Repeat step 5 for the other brush.
7. Assemble in reverse order.

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
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
compensate. 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.

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Troubleshooting (cont’d)
The following ow 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
NO
Is 115 VAC measured at
PGU board input?
Plugged into dead circuit,
bad power cord, or
switch is bad or off.
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.
NO Replace I/O board
assembly.
Does the green LED on
the I/O board light?
YES
YES
NO
YES
NO
Trips circuit breaker
Are the proper support rollers
and shoe groove being used
for the type and size of conduit
being 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
rectier
(91859972).
Are connectors corroded? YES Clean.
Replace PGU.
NO
NO
Won’t stop
YES Use 115 VAC.
Is the supply line voltage low?
YES Replace pendant
switch.
Does bender stop when the
pendant is unplugged?
Replace PGU.
NO
YES
Bender only runs in one direction
NO
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?
YES Replace
91866456 relay.
When amber or red LED is on, is
12 VDC measured at large relay
coil on PGU (where relay wire
unit connects)?
NO Replace I/O.
Move 6-wire connector on PGU
from “TO I/O” to “TEST.” Alternately
press BEND and UNLOAD. Does
yellow “DIRECTION” LED on PGU
turn on and off?
YES
Replace PGU.

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
12
1/2" to 1-1/4" Side Exploded View
7
19
204
205
206
5
26
23
43 Shoe Unit 1/2" to 1-1/4" consists
of 221, 222, 223, 224 and 225
223
225
224
222
225
221
205
206

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
1-1/2" to 2" Side Exploded View
3
74 96
91
92
26
224
226
227
228
229
44 Shoe Unit 1-1/2" to 2" consists
of 224, 226, 227, 228 and 229
The Roller Support Unit
exploded view is on
the following page.
97
226
158
157
163
160
155
159
154
164
156
165
167
166
161
162
215
207

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
14
1-1/2" to 2" Roller Support Unit Exploded View and Parts List
71 38221 50382217 Support weldment, roller....................... 1
72 00528 50005286 Support weldment, 1-1/2" .................... 1
73 00601 50006010 Support weldment, 2"........................... 1
74 38225 50382250 Arm weldment, adjustment ................... 1
75 00543 50005430 Plate, 1-1/2" outer roller....................... 1
76 00604 50006045 Plate, 2" outer roller.............................. 1
77 38254 50382543 Split rollers, 1-1/2" ............................... 2
78 38264 50382640 Ball, 1-1/2"........................................... 2
79 38255 50382551 Split rollers, 2"...................................... 2
80 38263 50382632 Ball, 2".................................................. 2
81 38262 50382624 Spacer, 2" roller.................................... 1
82 00599 50005995 Roller unit, 2"........................................ 1
83 00493 50004930 Shaft, 2" rear roller ............................... 1
84 38252 50382527 Roller, 1-1/2" IMC ................................. 1
85 38253 50382535 Roller, 2" Tail......................................... 1
86 38260 50382608 Shaft, 1-1/2" pivot roller ....................... 1
87 32027 50320270 Sleeve, 1-1/2" ...................................... 1
88 31728 50317288 Shaft, 2" pivot....................................... 1
89 38151 50381512 Sleeve, 2" ............................................. 1
90 23258 50232584 Grip....................................................... 1
91 38256 50382560 Shaft, eccentric..................................... 1
92 38251 50382519 Sleeve adapter...................................... 1
93 50540 90505409 Screw, 7/16-14 x 1.00 hex hd............... 2
94 00860 50008609 Shaft, 1-1/2" support............................ 1
95 54819 90548191 Retaining ring #5100-87....................... 2
96 54242 90542428 Screw, cap 1/4-20 x .37 btn hd............. 3
97 50224 90502248 Screw, 5/16-18 x 1.00 skt hd................ 1
98 50881 90508815 Screw, 1/4-28 x .25 set ........................ 2
99 53918 90539184 Washer, 1.00 x 1.37 x .03 shim............. 1
100 54248 90542487 Washer, Belleville 1.362 x .803 ............. 2
101 39440 50394401 Washer, .62 x 2.00 x .06 Flat................. 1
104 54243 90542436 Spring, extension .75 x 3.50.................. 2
105 54252 90542525 Clamp, loop-type................................... 1
115 38592 50385925 Guide, spring......................................... 1
116 51130 90511301 O-Ring, 1.50 x 1.62 x .062.................... 2
117 51537 90515374 O-Ring, 1.75 x 1.87 x .062.................... 2
118 38657 50386573 Shaft, 2 middle roller............................. 1
119 52644 90526449 Washer, 1/32 shim ................................ 1
150 52645 90526457 Washer, 1/16 shim ................................ 1
151 53216 90532163 Retaining ring #5100-62....................... 1
152 07323 50073230 Roller, 1.00 ........................................... 1
153 07322 50073222 Sleeve, .940.......................................... 1
178 55305 90553055 Screw, 7/16-14 x 1.75 .......................... 1
50005740 Roller Support Unit consists of:
UPC No.
Key 78-3310- Part No. Description Qty.
UPC No.
Key 78-3310- Part No. Description Qty.
95
118
89
73
98
117
71
104
84
72
115
86
116 78
77
100
77
78 98 116
87 94 75 93*
151 101 90
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
152
153
178*

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
15
Drive Unit Exploded View and Parts List
22
26
27
23
10
25
34
24 6
5
2
1
20
21
16
15
13
14
17
19 18
12
8
1
2
9
23
8
11
8A
22
Bolt Tightening Sequence for Gearbox Cover
6
4 3
1
25
1. Torque gearbox bolts to 11/9 Nm (100/80 in-lb) in
sequence shown.
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.
UPC No.
Key 78-3310- Part No. Description
1 86705 91867053 Commutator brushes
2 86706 91867061 Commutator 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 54348 90543483 Belleville washers
10 39073 50390732 Rear gear housing
11 39074 50390740 Gasket
12 39075 50390759 Front gear housing
13 39076 50390767 Output gear shaft
14 39077 50390775 Short spacer
15 39078 50390783 Long spacer
16 39079 50390791 2nd Reduction pinion shaft w/ BRGs
17 53323 90533232 Wave washer
18 39080 50390805 3rd Reduction pinion shaft w/ BRGs
19 54248 90542487 Belleville washer
20 39081 50390813 4th Reduction pinion shaft
21 39082 50390821 Small spacer
22 54043 90540433 1/2-20 x 2-1/2 Screw
23 02298 50022989 1/4-28 x 9-1/4" Stud
24 51705 90517059 1/4-28 hex nut
25 50749 90507495 1/4" Internal tooth lock washer
26 07208 50072080 Oil seal
27 07209 50072099 Oil seal

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
16
Main Exploded View
3
58
4, 4A
5
7
19
13
17
12
11
16
10
27
23
29
32
26
176
29
31
8
6
202
47
46
45
203
15
15
2
15
15
25
33
21
209, 211, 212
51
50
225
223
222
225
221
224
224
228
226
227
226
229
4C
4B
22
20A
14, 28
60
170
59
20
52
43
44
23
23
Power Cord
241
(place decal in
center on back)
37
170
30 233
233
26
165
167
166
169 168
167
166
173
UNLOAD
BEND
171
172
231
235 234 9
18
18
236
142
208
240
205
206
205
206
204
213
201
207
208
208
240

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
17
95
118
89
73
98
117
71
104
84
72
115
86
116 78
77
100
77 78 98 116
87 94 75 93*151 101 90
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. 500 0574.0
Roller Support Unit.
152
153
178*
106
107
96
92
91
21
74
97
6
158
157
163
160
159
164
156
155
154
161
162
If the chain breaks, replace it with a new
chain — not another master link — due
to the high stress on the chain. The
addition of a second master link will only
weaken the chain further. If the master
link breaks, replace it with a new master
link (90542517).
3
58
4, 4A
5
7
19
13
17
12
11
16
10
27
23
29
32
26
176
29
31
8
6
202
47
46
45
203
15
15
2
15
15
25
33
21
209, 211, 212
51
50
225
223
222
225
221
224
224
228
226
227
226
229
4C
4B
22
20A
14, 28
60
170
59
20
52
43
44
23
23
Power Cord
241
(place decal in
center on back)
37
170
30 233
233
26
165
167
166
169 168
167
166
173
UNLOAD
BEND
171
172
231
235 234 9
18
18
236
142
208
240
205
206
205
206
204
213
201
207
208
208
240

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
18
Main Parts List
UPC No.
Key 78-3310- Part No. Description Qty.
UPC No.
Key 78-3310- Part No. Description Qty.
2 01622 50016229 Frame weldment...................................... 1
3 38217 50382179 Guard weldment, top chain ...................... 1
4 38983 50389831 Guard assembly, front chain..................... 1
4A 38236 50382365 Guard, front ............................................. 1
4B 38244 50382446 Retainer................................................... 1
4C 50160 90501608 Rivet, 3/16" pop....................................... 2
5 38232 50382322 Guard weldment, motor ........................... 1
6 01607 50016075 Guard, bottom.......................................... 1
7 38199 50381997 Support weldment,
1/2" to 1-1/4" RLR .................................. 1
8 38250 50382500 Drive unit................................................. 1
9 01702 50017020 Spindle weldment, main .......................... 1
10 38193 50381938 Plate weldment, drive .............................. 1
11 54253 90542533 Sprocket, #60 14T ................................... 1
12 38267 50382675 Key, drive sprocket .................................. 1
13 54255 90542550 Bearing, sleeve #48DU40......................... 2
14 54250 90542509 Chain, #60 92P ........................................ 1
15 54462 90544625 Ring, retaining Truarc #5100-200 ............ 4
16 38265 50382659 Washer, main spindle............................... 2
17 38268 50382683 Key, shoe drive ........................................ 1
18 38457 50384570 Plate, hoist............................................... 2
19 55204 90552040 Pin, 1/2" to 1-1/4" support pivot.............. 1
20 38257 50382578 Spacer, motor mount ............................... 1
20A 39488 50394886 Spacer, thin motor mount......................... 1
21 38228 50382284 Locator weldment, eccentric.................... 1
22 54265 90542568 Nut, 1/2-13 lock ...................................... 1
23 51655 90516559 Screw, #10-16 x .50 hex head............... 31
25 53903 90539036 Screw, cap 1/2-13 x 1.00 ........................ 4
26 52501 90525019 Ring, retaining Truarc #5100-287 ............ 2
27 54345 90543459 Screw, set 1/2-20 x .75 socket ................ 1
28 54251 90542517 Link, connecting #60 chain...................... 1
29 52871 90528719 Screw, 1/4-20 x .75 socket...................... 4
30 03095 50030957 Pointer, 1/2" to 1-1/4" ............................. 1
31 03099 50030990 Pointer, 1-1/2" to 2" ................................ 1
32 03104 50031040 Spacer, pointer......................................... 2
33 52597 90525973 Washer, flat .56 x 1.37 x .109 .................. 4
37 54124 90541243 Strain relief.............................................. 1
43 38780 50387804 Shoe unit, 1/2" to 1-1/4" ......................... 1
44 38148 50381482 Shoe unit, 1-1/2" to 2" ............................ 1
45 52203 90522036 Screw, machine #6-32 x .25.................... 2
46 29708 50297082 Guard, breaker 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 w/ set screw ....................... 1
58 03129 50031295 Decal, angle............................................. 2
59 51751 90517512 Screw, drive............................................. 4
60 03101 50031015 Nameplate............................................... 1
62 38893 50078852 Decal, lifting eye (not shown) ................... 2
65 03105 50031058 Decal, select switch size
(not shown).............................................. 1
67 38898 50388983 Decal, bender pivot lock
(not shown).............................................. 1
68 38899 50388991 Decal, roller adjustment
(not shown).............................................. 1
69 02263 50022636 Decal, roller engagement
(not shown).............................................. 1
70 03100 50031007 Decal, operation (not shown).................... 3
71 38221 50382217 Support weldment, roller.......................... 1
72 00528 50005286 Support weldment, 1-1/2" ....................... 1
73 00601 50006010 Support weldment, 2".............................. 1
74 38225 50382250 Arm weldment, adjustment ...................... 1
75 00543 50005430 Plate, 1-1/2" outer roller.......................... 1
76 00604 50006045 Plate, 2" outer roller................................. 1
77 38254 50382543 Rol, 1-1/2"............................................... 2
78 38264 50382640 Ball, 1-1/2".............................................. 2
79 38255 50382551 Rol, 2" ..................................................... 2
80 38263 50382632 Ball, 2" .................................................... 2
81 38262 50382624 Spacer, 2" roller....................................... 1
82 00599 50005995 Roller unit, 2" .......................................... 1
83 00493 50004930 Shaft, 2" rear roller.................................. 1
84 38252 50382527 Roller, 1-1/2" IMC .................................... 1
85 38253 50382535 Roller, 2" tail............................................ 2
86 38260 50382608 Shaft, 1-1/2" pivot roller .......................... 1
87 32027 50320270 Sleeve, 1-1/2" ......................................... 1
88 31728 50317288 Shaft, 2" pivot.......................................... 1
89 38151 50381512 Sleeve, 2"................................................ 1
90 23258 50232584 Grip ......................................................... 1
91 38256 50382560 Shaft, eccentric........................................ 1
92 38251 50382519 Sleeve, adapter........................................ 1
93 50540 90505409 Screw, 7/16-14 x 1.00 hex head.............. 2
94 00860 50008609 Shaft, 1-1/2" support............................... 1
95 54819 90548191 Retaining ring #5100-100........................ 2
96 54242 90542428 Screw, cap 1/4-20 x .37
button head ............................................. 3
97 50224 90502248 Screw, 5/16-18 x 1.00 socket head ......... 1
98 50881 90508815 Screw, 1/4-28 x .25 set ........................... 2
99 53018 90539184 Washer, 1.00 x 1.37 x .03 shim................ 1
100 54248 90542487 Washer, Belleville 1.362 x .803 ................ 2
101 39440 50394401 Washer, .62 x 2.00 x .06 flat .................... 1

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
19
Main Parts List (cont’d)
UPC No.
Key 78-3310- Part No. Description Qty.
UPC No.
Key 78-3310- Part No. Description Qty.
104 54243 90542436 Spring, extension .75 x 3.50 .................... 2
105 54252 90542525 Clamp, loop-type ..................................... 1
106 52108 90521080 Nut, hex 1/4-20 ....................................... 1
107 54239 90542398 Screw, 1/4-20 x 3/4 ovl pt set.................. 1
115 38592 50385925 Guide, spring ........................................... 1
116 51130 90511301 O-ring, 1.50 x 1.62 x .062........................ 2
117 51537 90515374 O-ring, 1.75 x 1.87 x .062........................ 2
118 38657 50386573 Shaft, 2 middle roller ............................... 1
119 52644 90526449 Washer, 1/32 shim................................... 1
142 07887 50078879 Pendant control assembly........................ 1
143 07912 50079123 Power cord assembly............................... 1
150 52645 90526457 Washer, 1/16 shim................................... 1
151 53216 90532163 Retaining ring .......................................... 1
152 07323 50073230 Roller, 1.00 .............................................. 1
153 07322 50073222 Sleeve, .940............................................. 1
154 07314 50073141 Nest, spring ............................................. 1
155 07317 50073176 Rod, spring .............................................. 1
156 07318 50073184 Retainer, spring........................................ 1
157 07319 50073192 Pivot cam ................................................ 1
158 07321 50073214 Retaining cam ......................................... 1
159 55285 90552857 Spring...................................................... 1
160 55284 90552849 Spherical rod end,
1/4-28 thd male ...................................... 1
161 50985 90509854 Ring, retaining, 5100-100........................ 1
162 52749 90527496 Nut, self-locking, 3/8-24.......................... 1
163 55222 90552221 Screw, 5/16-18 x .75 skt hd cap.............. 1
164 55269 90552695 Bolt, 1/4-28 x .50 Gr #8, hex head ........... 1
165 55302 90553020 Screw, #6-32 x 1.25 skt hd mach ........... 2
166 38248 50382489 Back plate, switch ................................... 2
167 85822 91858224 Switch, limit #BZ-2RW822-A2 ................. 2
168 38246 50382462 Bracket, limit switch ................................ 1
169 54240 90542409 Screw, #6-32 x 1.00 skt hd mach ............ 2
170 86263 91862639 Nut, 1/2" conduit lock.............................. 1
171 86890 91868904 Ring, locking............................................ 1
172 86983 91869838 Boot, toggle, 1/2, black ............................ 1
173 54335 90543351 Screw, flange 1/4 x .37 thd ...................... 2
174 38974 50389742 Decal, circuit breaker (not shown)............ 1
176 54911 90549112 Screw, 1/4-28 x 3/8"
socket head cap ...................................... 2
177 01453 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
203 52031170 Tower weldment, R.H. trunnion ................ 1
204 53390 90533909 Wheel ...................................................... 2
205 38613 50386131 Axle, short ............................................... 2
206 51528 90515285 Ring, retaining #5160-75......................... 4
207 54237 90542371 Screw, flange 3/8-16 x 1.00 hx................ 8
208 52646 90526465 Nut, 3/8-16 Esna hex............................. 12
209 38167 50381679 Pin, trunnion lock..................................... 1
211 54244 90542444 Spring, trunnion lock................................ 1
212 38168 50381687 Knob........................................................ 1
213 52031172 Caster w/side lock .................................. 2
221 31710 50317105 1/2" to 1-1/4" IMC, Rigid hook ................ 1
222 33494 50334948 1/2" to 1-1/4" Shoe................................. 1
223 31712 50317121 1/2" to 1-1/4" EMT hook ......................... 1
224 52479 90524799 Drive bolt, 1/2-13 x .62
socket head cap screw ............................ 6
225 51088 90510887 1/2" to 1-1/4" Hook bolts,
3/8-16 x 1-1/4
socket head cap screw ............................ 8
226 53396 90533968 1-1/2, 2" Hook shoulder bolts,
3/4 x 1-1/2 ............................................. 6
227 38147 50381474 1-1/2, 2" shoe ......................................... 1
228 31716 50317164 1-1/2, 2" EMT hook................................. 1
229 38779 50387790 1-1/2, 2" IMC and rigid hook ................... 1
231 07942 50079042 Selector switch unit ................................. 1
234 50645 90506456 Nut, 5/16-18 reg jam............................... 2
235 50224 90502248 Screw, 5/16-18 x 1, socket head ............. 2
236 54355 90543556 Washer, flat .158 x .380 x .050 ................ 4
240 52031173 Flange, screw ......................................... 4
241 52025721 Decal, warning......................................... 1
07248 50072486 Decal, extension cord (not shown)............ 1
Optional
38962 50389629 Vinyl cover (not shown)
01700 50017004 1/2" to 2" PVC shoe group
Service Only
05586 50055860 Frame unit (includes bearings)................. 1
52033403 Service kit (includes base
and LH & RH trunnions) ....................... 1
233

854 Quad Bender
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
20
Wiring Diagram
120D
120C
120B
120A
121
51
TO BRAKE
123
GREEN
WHITE
BLACK
TO DRIVE UNIT
122 143
GREEN
WHITE
BLACK
BLACK
WHITE
BLACK
RED
TO I/O
TO RELAY
BLACK RED
BLACK
RED
FROM RECTIFIER
YELLOW
BLACK
RED
WHITE
WHITE
+HV
-HV
AC
AC
YELLOW
YELLOW
YELLOW
CN2
CN1
JP1 GREEN
BLACK
47
23
COM NO NC NC
NO
COM
BLACK
BLACK
WHITE
WHITE
167
(LOCATED UNDER TOP COVER)
167
(LOCATED UNDER ROLLER SUPPORT)
TO PENDANT
170
172
231
171
120
XX