Greenlee 853, 853 Quad Bender Service Manual

Page 1

SERVICE MANUAL

Quad Bender

853

™

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

Page 2

853 Quad Bender™

Table of Contents

Safety .............................................................................2

Purpose .......................................................................... 2

Other Publications .......................................................... 2

Important Safety Information ....................................... 3-4

Handle Removal and Replacement ............................... 5

Transporting the Bender ................................................ 5

Maintenance................................................................6-8

Troubleshooting ........................................................ 9-11

Exploded Views and Parts List................................12-19

Electrical Control Layout .............................................. 20

I/O Electrical Schematic ..........................................21-22

PCB Layout ..................................................................23

Power Generation Unit ............................................ 24-27

Purpose

This manual is intended to familiarize all personnel with the safe service procedures for the following Greenlee tools:

853 Quad Bender (beginning with Serial Number ADW0000)

Keep this manual available to all personnel. Replacement manuals are available upon request

at no charge. The Greenlee 853 Quad Bender is protected by

U.S. Patent No. 5,226,305.

Other Publications

Instruction Manual: Publication 999 3876.6 (IM 1527)

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.

Greenlee / A Textron Company 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 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, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result in severe injury or death.

853 Quad Bender™

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 from power before servicing.

Failure to observe this warning could 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 hazardous environment. Hazards include flammable liquids, gases, or other materials. Using this tool in a hazardous environment can result in a fire or explosion.

Failure to observe this warning will result in severe injury or death.

• Do not expose to rain.

• Do not use in wet or damp locations.

Failure to observe these warnings can 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 flying debris.

Do not remove guards. Failure to observe this warning could

result in severe injury or death.

Greenlee / A Textron Company 3 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 4

853 Quad Bender™

IMPORTANT SAFETY INFORMATION

Extension cords:

• Use only three-wire, 12-gauge extension cords that have threeprong 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 can result in severe injury or death.

Make sure that the handle is properly installed and secured with the safety spring clips and snap pins before lifting or moving the bender. An improperly installed handle could allow the bender to fall, injuring nearby personnel.

Failure to observe this warning can result in severe injury or death.

• 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 replacement parts. A damaged or improperly assembled 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 this tool for the manufacturer’s intended purpose only. Use other than that which is instructed in this manual can result in injury or property damage.

Failure to observe these precautions can result in injury or property damage.

Pinch points: Keep hands away from bending

shoe, rollers and conduit when bender is in use.

Unplug the bender before changing accessories. Accidental startup can result in serious injury.

Greenlee / A Textron Company 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 5

853 Quad Bender™

Handle Removal and Replacement

The handle of the 853 is removable. This feature is convenient when performing complex bending, and makes it easy to replace a damaged handle.

Removal

1. Place the bender in the upright position.

2. Release the spring clip on the safety snap pin.

3. Remove the pin from the handle and the sleeve of the frame.

4. Repeat for the other end of the handle.

5. Lift the handle to remove.

Replacement

1. Insert the handle into the sleeves of the frame.

2. Align the holes in the handle with the holes in the sleeves.

3. Insert the safety snap pin. Ensure that the pin goes through the handle and the sleeve on the frame.

4. Engage the safety spring clip over the end of the pin. Ensure that the loop on the clip is completely around the pin.

5. Repeat for the other end of the handle.

Transporting the Bender

Make sure that all components used to lift this bender are properly rated for the 202 kg (445 lb) weight. Use a ramp to load and unload the bender from a truck or other vehicle that is not equipped with a lift gate.

To lift the bender, loop a nylon or polyester sling through the spindle. Thread one end of the sling through the length of the spindle as shown. Securely fasten to lifting device.

Lifting Bender

Removing or Replacing Handle

safety

snap

Failure to observe this warning can result in severe injury or death.

Lift bender using a nylon or polyester sling through the spindle. Do not attempt to lift bender by the handles. Make sure all lifting components are properly rated for the 202 (445 lb) weight.

Failure to observe this warning can result in severe injury or death.

Greenlee / A Textron Company 5 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 6

Maintenance

There is no need for periodic flushing and replacing of lube in the bender gear box since it is sealed and locked tight. However, if the box is opened for repair and the lube is lost or contaminated by dirt, then the box and parts should be flushed out and filled with 26 fluid ounces of Mobil® 634 synthetic oil.

Flushing should be accomplished with kerosene, which is a petroleum hydrocarbon that does not affect seals.

Note: Aromatic hydrocarbons such as benzine, chlorinated solvents such as carbon-tetrachloride, and ketones such as acetone should never be used for flushing as they are solvents for rubber. They are also harmful to the environment.

Chain Adjustment

853 Quad Bender™

Eight Reductor Mounting Bolts (four on reverse side)

Disconnect this tool when not in use, before servicing or adjusting, and when changing shoes or conduit rollers and supports.

Failure to observe this warning could result in severe injury or death.

Both chains have to be adjusted if the final drive #60 chain is to be reset. Refer to the Exploded View and Parts List.

Remove the front cover (38) and upper rear guard (37).

2. Loosen the eight mounting bolts for the reductor (19). Remove the eccentric cam and move the reductor to create chain slack.

3. Remove the four retaining screws for eccentric adjustment. Rotate to remove slack from the chain and align with one of the two sets of holes in the frame. Remount the eccentric with the four bolts.

4. Slide the reductor in slotted mounting holes to the retension chain. Set tension with the eccentric cam.

With the eight reductor mounting bolts (22, 24) loose, rotate the eccentric cam with a 1/2" square drive to tension the chain. Torque the eight reductor mounting bolts to 47 Newton-meters (35 ft-lb).

Two eccentric cam mounting holes provided for varying

Reductor Mounting Bolt

1/2" Square

Rotate eccentric cam counterclockwise. Apply 20 Newton-meters (15 foot-pounds) of torque to set chain tension. Then torque reductor mounting bolts to 47 Newton-meters (35 foot-pounds).

adjustment positions.

Eccentric Cam

Tab on Reductor Bracket

Greenlee / A Textron Company 6 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

#60 HT Final Drive Chain

Positioning Plate on Eccentric Housing, Counter Shaft

Four 1/4" Flange Mounting Screws

Page 7

Maintenance (cont’d)

Electrical Control Unit Removal

Disconnect power supply before servicing bender. Servicing to be done only by trained service technician.

Failure to observe this warning could result in severe injury or death.

853 Quad Bender™

Electric shock hazard: Disconnect the unit from power

before servicing. Failure to observe this warning can

result in severe injury or death.

1. Remove the cover retained by ten 5/16" hex screws.

2. Disconnect the pendant switch plug from the circuit board and remove through the cord grip.

3. Remove two hex mounting screws, one on each side.

3/8" Hex

Mounting Screw

4. Remove the motor leads, power cord ground wire, and neutral wire before the control unit can be totally removed from the bender.

Line Connection

at Circuit Breaker

Wear eye protection when operating or servicing this tool.

Failure to wear eye protection can result in serious eye injury from flying debris.

Roller Support Maintenance

Clean and lubricate roller supports every 6 months, or more often if the bender is used in dusty or corrosive environments.

Refer to the exploded view of the bridge assembly when performing the following procedures.

1" Roller Support

1. Disconnect the bender from the power source.

2. Remove shoulder bolt (40) and nut (41). Remove 1" arm (1).

3. Remove retaining ring (39). Remove 1" roller (5).

4. Spray a motorcycle chain or high quality axle grease on shaft of the 1" arm (1).

5. Lubricate the shoulder bolt (40).

6. Wipe away any excess lubricant.

7. Assemble in reverse order.

Greenlee / A Textron Company 7 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 8

Maintenance (cont’d)

853 Quad Bender™

1-1/4" to 2" Roller Support

1. Disconnect the bender from the power source.

2. Remove the shoe and bridge assembly.

3. Place bridge on stable work surface. Use a pair of needlenose pliers to disconnect the spring (48) from the hole in the bridge beneath the roller support unit.

4. Remove the squeeze adjustment arm screw (38) and arm (32).

5. Remove the three button head cap screws (37) and adapter sleeve (33).

6. Place one hand under the support arm (2) to support the weight of the roller support unit. Remove the eccentric shaft (4).

Note: You may need to rotate the eccentric shaft to remove it.

Pinch points: Use both hands to hold the lead and

tail rollers to prevent the rollers from pivoting.

Failure to observe this precaution could result in injury or property damage.

7. Lift bridge weldment (3) off of roller assembly.

8. To separate 1-1/4" and 1-1/2" roller assemblies: Loosen the sleeve set screw (36) and remove the 1-1/4" to 1-1/2" pivot roller shaft (28). Remove the sleeve (30).

9. On the 1-1/4" roller group:

• Remove two hex head screws (34). Remove the

outer roller plate (14).

• Remove the tail roller (7) and lead roller (6).

10. On the 1-1/2" roller group:

• Remove two hex head screws (34). Remove the

outer roller plate (14).

• Remove the tail roller (10).

• Remove all components of the split roller

assembly.

11. On the 2" roller group:

• Loosen the sleeve set screw (36) and press out the 2" pivot shaft (29). Remove the sleeve (31).

• Remove the hex head screw (34). Remove one retaining ring (35) from the tail roller shaft (26). Remove outer roller plate (15).

• Remove the tail roller (9) and center roller (8).

• Remove all components of the split roller assembly.

12. Clean off all of the grease and dirt.

13. Inspect each item. Replace any worn, damaged, or missing items.

14. Lubricate all working surfaces with a high-quality grease.

15. Replace all components in reverse order, noting the following:

• On split 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 (42, 43, or 44) as needed.

• On the 1-1/2" roller group: Install the two Belleville

washers (21) so that the inside diameters contact each other.

• Use Loctite® 271 on the hex head screws (34).

Torque to 55 to 61 Nm (40 to 45 ft-lb).

16. Position the roller support arm (2) as shown. Assemble the roller groups to the support arm.

17. Place the bridge weldment (3) over roller assembly.

18. Insert the eccentric shaft (4).

Note: You may need to rotate the eccentric shaft to get it to seat completely.

19. Install the adapter sleeve (33) and three button head cap screws (37).

20. Install the adjustment arm (32) and adjustment arm screw (38).

21. Attach the spring (48) to the holes in the bridge beneath the roller support unit.

Greenlee / A Textron Company 8 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 9

853 Quad Bender™

Troubleshooting

Problem Probable Cause Possible Remedy

Bender will not operate. No voltage. Check supply voltage circuit operation.

Check that switch is on.

Bends are overbent a few Pointer is adjusted wrong. Loosen pointer locking screws and degrees. rotate clockwise to compensate.

Retighten locking screws.

Too much squeeze on 1-1/4", 1-1/2" Back squeeze off per adjustment or 2" EMT, IMC or Rigid Aluminum instructions. conduit.

Unusual conduit characteristics. Bend smaller angle to compensate.

Bends are underbent a few Pointer is adjusted wrong. Loosen pointer locking screws and degrees. rotate counterclockwise to compen-

sate. Retighten locking screws.

Too little squeeze on 1-1/4", 1-1/2" Increase squeeze per adjustment or 2" EMT, IMC or Rigid Aluminum instructions. conduit.

Unusual conduit characteristics. Bend larger angle to compensate.

Bender stops bending. Current overload. Rigid conduit is being bent with roller

support engaged. Retract roller assembly. Conduit is bent past 105° and hook has contacted unbent conduit. Press UNLOAD and remove overbent conduit.

Greenlee / A Textron Company 9 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 10

Troubleshooting (cont’d)

853 Quad Bender™

The following flow charts show the suggested troubleshooting 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.

Won’t bend

Plugged into dead circuit,

Is 115 VAC measured at PGU BOARD input?

YES

Does the green LED on the I/O BOARD light?

YES

Does the green LED on the PGU light?

YES

Does amber or red LED on IO light when BEND or UNLOAD is pressed?

YES

Does relay on IO operate when BEND or UNLOAD is pressed?

YES

Replace PGU.

bad power cord, or switch is bad or off.

Replace transformer unit.

Replace PGU.

Unplug pendant or IO and

check switch for continuity. If ok, replace IO.

Replace IO.

Trips circuit breaker

Are the proper support rollers and shoe groove being used for the type and size of conduit being bent?

YES

Is the current on the 115 VAC line exceeding 20 amps?

YES

Is the DC current to the motor exceeding 17 amps?

When BEND is pressed, is the voltage sent to the motor 20 to 50 volts over the AC line voltage?

YES

Are connectors corroded?

Replace PGU.

YES

Won’t stop

Is the supply line voltage low?

Does bender stop when the pendant is unplugged?

Replace PGU.

YES

Bender only runs in one direction

Does amber or red LED light when switch is pressed?

YES

When amber or red LED is on, is 12 VDC measured at large relay coil on PGU (where relay wire unit connects)?

YES

Replace 918 6645.6 relay.

Follow directions in instruction manual.

Replace circuit breaker.

Replace motor.

Replace bridge rectifier (918 5997.2).

Clean.

Use 115 VAC.

Replace pendant switch.

Check and replace pendant switch.

Move six-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?

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

NOYES

Replace PGU. Replace I/O.

Page 11

Quick diagnostics for electronic problems

1. With bender unplugged, switch six-wire connector on PGU from “To I/O” to “Test.”

2. Plug unit in.

3. Press BEND. Contactor on I/O will activate.

• If not, check for 12 VDC at contactor coil — If 12 VDC is present, replace contactor

918 6645.6—else replace I/O

• If bender runs, replace PGU.

• On PGU near “test” connector: Green “Power” LED is ON

Yellow “Direction” LED is OFF Red “PWM” LED slowly turns dimly on

If not, replace I/O.

4. Press UNLOAD. Contactor on I/O will activate.

• If not, check for 12 VDC at contactor coil — If 12 VDC is present, replace contactor

918 6645.6—else replace I/O

• On PGU near “test” connector: Green “Power” LED is ON

Yellow “Direction” LED is ON Red “PWM” LED slowly turns dimly on

If not, replace I/O.

5. Press BEND. With insulated object, carefully press black button “S1” on PGU. Bender will run slowly. If not, replace PGU.

853 Quad Bender™

Greenlee / A Textron Company 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 12

Exploded View — 853 Quad Bender

Note: Key supplied

with item #19

(reductor)

853 Quad Bender™

141

142

BEND

UNLOAD

Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 13

Parts List — 853 Quad Bender

Key Part No. Description Qty.

1 500 7275.7 Weldment, main frame ...................................................................... 1

2 502 3452.8 Washer, fiber ..................................................................................... 1

3 500 7277.3 Weldment, sprocket unit .................................................................... 1

5 905 2410.1 Bearing, Fiberglide ø2.625 x 3.75 long ............................................. 2

6 905 2414.4 Ring, retaining #5100-237 ................................................................. 1

7 905 2412.8 Bearing, Fiberglide ø1.625 x 1.00 long ............................................. 2

8 503 9763.0 Weldment, countershaft .................................................................... 1

9 905 4023.9 Ring, retaining #5100-250 ................................................................. 1

10 503 9764.8 Shaft, counter .................................................................................... 1

11 905 2413.6 Bearing, thrust Fiberglide .................................................................. 2

12 905 4548.6 Sprocket, #40 60T ............................................................................. 1

13 905 4253.3 Sprocket, #60 14T ............................................................................. 1

14 503 9765.6 Key, countershaft .............................................................................. 2

15 905 4546.0 Chain, #60 87P.................................................................................. 1

16 905 4251.7 Masterlink, #60 .................................................................................. 1

17 905 4547.8 Sprocket, #40 13T ............................................................................. 1

18 500 8431.3 Key, reductor sprocket ...................................................................... 1

19 905 2388.1 Reductor, worm gear ......................................................................... 1

20 905 2787.9 Masterlink, #40 .................................................................................. 1

21 905 4551.6 Chain, #40 87P.................................................................................. 1

22 905 4568.0 Bolt, 3/8–16 UNC x .75...................................................................... 7

23 503 9758.3 Eccentric............................................................................................ 1

24 905 4237.1 Bolt, 3/8–16 UNC x 1.00.................................................................... 6

25 918 6973.0 Motor ................................................................................................. 1

26 905 4549.4 Conduit, Sealtight .............................................................................. 1

27 918 5214.5 Elbow, Sealtight................................................................................. 1

28 918 6683.9 Strain relief ........................................................................................ 1

29 905 1170.0 Nut, 3/4 conduit lock .......................................................................... 1

31 918 6263.9 Nut, 1/2 conduit lock .......................................................................... 1

32 503 9757.5 Axle ................................................................................................... 1

34 905 1528.5 Ring, retaining #5160-75 ................................................................... 2

35 905 5267.9 Wheel, urethane-filled ....................................................................... 2

36 503 9768.0 Guard, rear lower .............................................................................. 1

37 503 9769.9 Guard, rear upper .............................................................................. 1

38 503 9760.5 Cover, front........................................................................................ 1

39 905 1655.9 Screw, #10–16 x .50 hex head ........................................................ 31

40 905 0430.5 Screw, #6–32 x .375 Phillips ............................................................. 2

41 918 6385.6 Switch, air pax ................................................................................... 1

42 502 9708.2 Guard, switch .................................................................................... 1

43 500 7920.4 Nameplate ......................................................................................... 1

44 905 3001.2 Rivet, pop 1/8 x 1/8 drive................................................................... 4

45 500 7248.6 Decal, voltage.................................................................................... 1

46 503 0392.9 Decal, damp warning......................................................................... 1

47 503 9759.1 Cover, top .......................................................................................... 1

48 503 5191.5 Decal, safety...................................................................................... 1

853 Quad Bender™

Greenlee / A Textron Company 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 14

Parts List — 853 Quad Bender (cont’d)

Key Part No. Description Qty.

49 905 3389.5 Pin, hitch............................................................................................ 1

52 905 4552.4 Lanyard ............................................................................................. 2

54 905 4335.1 Screw, 1/4 x .37 thread-forming ........................................................ 6

58 503 8974.2 Decal, circuit breaker......................................................................... 1

59 905 5323.3 Pin, Driv-Lok, 1/8 x 1/2 ...................................................................... 1

70 905 1740.7 Washer, flat ....................................................................................... 2

71 500 7935.2 Decal, instruction ............................................................................... 1

72 503 9918.7 Decal, warning (English) ................................................................... 1

73 500 0112.4 Decal, warning (French) .................................................................... 1

74 500 8380.5 Decal, proper Lifting .......................................................................... 1

75 500 3141.4 Decal, FCC Part 15 ........................................................................... 1

76 999 3576.7 Decal, technical assistance ............................................................... 1

77 905 1051.8 Ring, retaining #5100-150 ................................................................. 2

78 905 5268.7 Pin, safety snap ................................................................................. 2

79 503 9748.6 Handle, upper .................................................................................... 1

80 500 6919.5 Sleeve, axle ....................................................................................... 2

88 500 8189.6 Bracket, locator ................................................................................. 1

89 905 2646.5 Nut, 3/8" - 16 ..................................................................................... 1

853 Quad Bender™

141 500 7869.0 Electronic control assembly (fully assembled) .................................. 1

141A 500 7871.2 I/O control assembly..................................................................... 1

141B 500 8357.0 Power generation unit................................................................... 1

141C 500 7867.4 Bracket, electronics (metal bracket only)...................................... 1

142 500 7887.9 Pendant control assembly ................................................................. 1

143 500 7912.3 Power cord assembly ........................................................................ 1

Greenlee / A Textron Company 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 15

Exploded View—500 7276.6 Bridge Assembly

853 Quad Bender™

Greenlee / A Textron Company 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 16

Exploded View—500 7276.6 Bridge Assembly (cont’d)

For all #34 screws: apply a high-strength thread-locking agent such as Loctite 271 to the threads and then tighten to 45 ft-lb.

853 Quad Bender™

Use slim washers #42, #43, #44 between the 2" ball (#19) and outer plate (#15) to allow free movement of the split roller with no more than 1/32: axial free play.

Greenlee / A Textron Company 16 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 17

Parts List—500 7276.6 Bridge Assembly

Key Part No. Description Qty.

1 500 7239.0 1" Arm weldment ............................................................................... 1

2 500 7247.1 Arm weldment ................................................................................... 1

3 500 7284.6 Bridge weldment................................................................................ 1

4 500 7258.7 Shaft eccentric................................................................................... 1

5 500 7259.5 Roller, 1" ............................................................................................ 1

6 500 7261.7 Roller, 1-1/4" lead .............................................................................. 1

7 500 7262.5 Roller, 1-1/4" tail ................................................................................ 1

8 500 0559.5 Roller unit, 2" ..................................................................................... 1

9 503 8253.5 Roller, 2" tail ...................................................................................... 1

10 503 8252.7 Roller, 1-1/2" IMC .............................................................................. 1

11 500 7264.1 Support weldment, 1-1/4" .................................................................. 1

12 500 0528.6 Support weldment, 1-1/2" .................................................................. 1

13 500 0601.0 Support weldment, 2" ........................................................................ 1

14 500 0543.0 Plate, 1-1/2" outer roller .................................................................... 2

15 500 0604.5 Plate, 2" outer roller ........................................................................... 1

16 503 8254.3 Rol, 1-1/2" ......................................................................................... 2

17 503 8264.0 Ball, 1-1/2" ......................................................................................... 2

18 503 8255.1 Rol, 2" ................................................................................................ 2

19 503 8263.2 Ball, 2" ............................................................................................... 2

20 503 8262.4 Spacer, 2" roller ................................................................................. 1

21 905 4248.7 Washer, Belleville 1.362 x .803 ......................................................... 2

22 905 1130.1 O-ring, 1.50 x 1.62 x .062 .................................................................. 2

23 905 1537.4 O-ring, 1.75 x 1.87 x .062 .................................................................. 2

24 500 7266.8 Shaft,1-1/4" support .......................................................................... 1

25 500 0860.9 Shaft, 1-1/2" support ......................................................................... 1

26 500 0493.0 Shaft, 2" rear roller ............................................................................ 1

27 503 8657.3 Shaft, 2" middle roller ........................................................................ 1

28 500 7265.0 Shaft, 1-1/2" pivot roller ..................................................................... 1

29 503 1728.8 Shaft, 2" pivot .................................................................................... 1

30 503 2027.0 Sleeve, 1-1/2" .................................................................................... 1

31 503 8151.2 Sleeve, 2" .......................................................................................... 1

32 503 8225.0 Arm, adjustment ................................................................................ 1

33 503 8251.9 Sleeve, adapter ................................................................................. 1

34 905 0540.9 Screw, 7/16-14 x 1.00 hex head ....................................................... 5

35 905 4819.1 Retaining ring, #5100-87 ................................................................... 2

36 905 0881.5 Screw, 1/4-28 x .25 set...................................................................... 2

37 905 4242.8 Screw, 1/4-20 x .38 button head ....................................................... 3

38 905 5282.2 Screw, 5/18 wing ............................................................................... 1

39 905 0283.3 Retaining ring, #5100-75 ................................................................... 1

40 905 5293.8 Shoulder bolt, 1/2" x 2.00 .................................................................. 1

41 905 0639.1 Nut, 3/8-16 hex .................................................................................. 1

42 905 3918.4 Washer, 1.00 x 1.37 x .030 shim ....................................................... 1

43 905 2644.9 Washer, 1/32 shim ............................................................................ 1

44 905 2645.7 Washer, 1/16 shim ............................................................................ 1

45 500 7464.4 Flip Stop ............................................................................................ 1

46 905 5303.9 Screw, 1/4-20 x .25 button head ....................................................... 2

47 503 8592.5 Guide, spring ..................................................................................... 1

48 905 4243.6 Spring, extension............................................................................... 1

49 503 8899.1 Decal, roller adjustment..................................................................... 1

50 500 7921.2 Decal, roller engagement .................................................................. 1

51 500 7936.0 Decal, 1" roller ................................................................................... 1

52 500 8190.0 Block, locator ..................................................................................... 1

53 905 4237.1 Screw, 3/8-16 x 1.00 hex .................................................................. 1

853 Quad Bender™

Greenlee / A Textron Company 17 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 18

Exploded View/Parts List—500 7271.4 Shoe Assembly

Bending Shoe 1" to 2" EMT, IMC and Rigid Conduit

Key Part No. Description Qty.

1 500 7271.4 Bending shoe assembly

(includes items 2–10) .......................... 1

2 500 7160.2 Hook, EMT ........................................... 1

3 500 7162.9 Hook, IMC/RIGID................................. 1

4 905 3396.8 Bolt ...................................................... 6

5 502 3422.6 Stud, drive ........................................... 4

6 500 7281.1 Pointer ................................................. 2

7 500 7270.6 Screw, 1/4 - 20 x .38 ........................... 2

8 500 7933.6 Decal, 1" - 2" EMT ............................... 1

9 500 7934.4 Decal, 1" - 2" IMC/RIGID ..................... 1

10 500 8381.3 Decal, shoe weight .............................. 2

853 Quad Bender™

NOTE: Second decal on opposite hook in same location

Greenlee / A Textron Company 18 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 19

Exploded View/Parts List—115 Volt Motor

Torque to

117

102

117

9 Newton-meters (80 inch-pounds)

103

104

117

105

116

106

107

108

109

117

110

853 Quad Bender™

115

101

111

112

113

114

Pacific Scientific

Key Part No. Description Qty.

101* 918 6417.8 Motor, 115 volt (standard) (SRF-3745-4676-2-56C) ...... 1

102 918 6471.2 Fan cover ........................................................................1

103 905 5071.4 Retaining ring.................................................................. 1

104 918 6432.1 Fan .................................................................................. 1

105 918 6428.3 End bell nut ..................................................................... 2

106 918 6419.4 Bell, rear end...................................................................1

107 918 6420.8 Brush............................................................................... 2

108 918 6422.4 Thrust washer .................................................................1

109* 918 6427.5 Shell and magnet assembly, 115V .................................1

110* 918 6425.9 Armature, 115V ............................................................... 1

111 918 6421.6 Bearing kit .......................................................................2

112 918 6418.6 Bell, front end.................................................................. 1

113 918 6424.0 Retaining ring.................................................................. 1

114 918 6426.7 Tie bolt, 115V.................................................................. 2

115 918 5876.3 90° Connector ................................................................. 1

116 918 6430.5 Brush cover ..................................................................... 2

117 918 6431.3 Cover screw .................................................................... 7

* Note: Alternate motor. Check motor part number before ordering magnet shell or armature.

101 918 6973.0 Motor (SRF-3648-5532-7-56C) 109 918 6975.7 Shell and magnet assembly 110 918 6974.9 Armature

Greenlee / A Textron Company 19 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 20

Electrical Control System Layout

853 Quad Bender™

141C

(bracket only)

141B

72, 65

141

(fully assembled)

141A

TO MOTOR (25)

WHITE

BLACK

GREEN

WHITE

BLACK

(143)

POWER CORD

GREEN WHITE BLACK

Greenlee / A Textron Company 20 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

(142)

TO PENDANT

LINE

LOAD

Page 21

I/O Electrical Schematic (500 7871.2)

853 Quad Bender™

+5V +12V

10K

R23

JP2

MECHANICAL BRAKE

Molex 39-28-1023

UF1001DI

R10

+5V

TIP122

JP4

150

+12V

10K

470

JP1

54321

DC POWER IN

Molex 26-60-4050

POWER

GREEN LED

330

R22

JP3

RELAY COIL

Molex 39-28-1023

UF-1001-DI

+12V+12V+5V

470

R14

DIR B

AMBER LED

10K

R18

PENDANT

Molex 39-28-1043

DIR A

RED LED

10K

R17

10K

R16

10K

R15

PN2222A

_RUN/BRAKE__DIRECTION_

.1uF/50V

R21

R20

330

Note: All resistors 5% 1/4W unless noted.

+12V

4.0 MHz

10K

+5V

10K

RUN/BRAKE

DIR B

DIR A

PWM

DIRECTION

MECH BRAKE

UNUSED2

UNUSED1

OSC2/CLKOUT

+5V

RA1/AN117RA0/AN0

10K

1N4148

RA3/AN3

RA4/TOCKI

RA2/AN2/VREF

RB0/INT

OSC1/CLKIN

MCLR

.1uF/50V

4.7uF/50V

RB712RB611RB510RB49RB38RB27RB1

PIC16C620

UF-1001-DI

470

R13

150

R12

470

R11

PN2222A

_PWM_

R19

JP5

654321

TO PGU

Molex 39-28-1063

Greenlee / A Textron Company 21 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 22

853 Quad Bender™

I/O Electrical Schematic (500 7871.2) Parts List

Reference Supplier Part Number Description Qty.

C1,C3,C4 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 3

AVX SA115C104KAA

KEMET C420C104K5R5CA C2 Panasonic ECE-A50Z4R7 Capacitor, 4.7 uF, 50 volts 1 D1,D4,D5 Diodes Inc. UF-1001-DI Diode, Ultra-Fast Switching Rectifier 3 D2 Panasonic LN38GP LED, T1, Green 1

Liteon LTL-4231 D3 Generic 1N4148 Diode 1 D6 Panasonic LN28RP LED, T1, Red 1

D7 Panasonic LN48YP LED, T1, Amber 1

JP1 Molex 26-61-4050 Connector, Locking, 0.156" cc, 5-position, Gold 1 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 TIP122 Transistor, NPN 1 Q1–Heat Sink Hardware AAVID 577002B04000 Heat Sink, TO-220, .75 x .52 x .25", with Tab 1

Q2,Q3,Q4 Generic PN2222A Transistor, NPN 3 R1,R2,R3,R4,R7,R8,R15, Generic Resistor, 10K, 1/4 watt, 5% 12

R16,R17,R18,R22,R23 R5,R11,R13,R14 Generic Resistor, 470 Ω, 1/4 watt, 5% 4 R6,R20,R21 Generic Resistor, 330 Ω, 1/4 watt, 5% 3 R9,R19 Generic Resistor, 1 kΩ, 1/4 watt, 5% 2 R10,R12 Generic Resistor, 150 Ω, 1/4 watt, 5% 2 U1 Greenlee 91869382 Processor, Programmed, 854 1 X1 Murata CST4.00MGW Resonator, 4.0 Mhz 1

Liteon LTL-4221

Liteon LTL-4251

Generic #4-40 Lock Washer Stainless Steel, Split Ring or Internal Tooth 1

Generic #4-40 Hex Nut Stainless Steel 1

Generic #4-40 Phillips Screw Stainless Steel, Machine, Pan Head, #4-40 x 0.25" 1

Panasonic EFO-GC4004A4

Greenlee / A Textron Company 22 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 23

PCB Layout (500 7871.2)

853 Quad Bender™

JP1

JP5

456

TO PGU

R20

R10 C3

JP4

R17 R18 R15

R21

R16

SELECTOR

DIR B

DIR A

POWER

RELAY

JP3

R1 R2

R5 R14 R13 R11 R8

R12

BRAKE

R19

R22

R23

R9 R7 R4 R3

JP2

Greenlee / A Textron Company 23 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 24

Power Generation Unit Schematic Diagram (500 8357.0)

BLACK

J11

RED

#4-40 Phillips Screw

#4-40 Nut

#4-40 Lock Washer:

#4-40 Flat Washer (x2)

KA-118-094

Power Devices, Inc

Insulator:

THM7023B-MT

Thermalloy Inc.

Heatsink:

Mounting Hardware for Q1 and D8

Do not trim insulator.

in heat sink.

Q1 should mount to upper hole

in heat sink.

D8 should mount to lower hole

Tighten Q1 and D8 to 5 in-lb

J10

+170 V

TO RELAY (Contacts 6 and 7)

DSEI30-06A

TO RELAY (Contacts 5 and 8)

IXFK73N30

1N5245B

.040/5W/1%

R15

853 Quad Bender™

+15 V

1uF/63V

.1uF/50V

4.75K/1%

20K/1%

12K/1%

150K

R41M

1N4148

R11

MIC4422BN

1.5K/1%

R26

100K

U1B

LM339

123

10K/1%

R16

1N4148

100K

R13

R14

123

R12

EVQ-PAC09K

1N4148

.01uF/50V

+15 V

LM339

U1A

R10

R24

20K/1%

567

U1D

LM339

+15 V

123

R25

R29

10K/1%

68.1K/1%

R22

R23

18.7K/1%

R27

LM339

U1C 100/1%

TO RELAY COIL (Contacts 1 and 2)

Molex 39-28-1023

10K/1%

D13

C12

R28

123

.1uF/50V

1.5K/1%

+15 V

R17

1N4007

4.7K/10W

D14

+170 V

1N4007

C10

C71000uF/250V

680uF/25V

D10

1N5245B

POWER

GREEN LED

D11

20K/2W/1%

R18

RECTIFIER

C11

.010uF/500VAC

470uH

DC+

RED

TO BRIDGE

YELLOW

.010uF/500VAC

1.5M

R20

.1uF/50V.1uF/50V

+15 V

DC-

BLACK

YELLOW

Notes:

• Bend leads on R17 to mount at least 0.25" off-board.

• All resistors 5% 1/4W unless noted.

C13

DIRECTION

YELLOW LED

PWM

RED LED

654321

TEST CONNECTOR

Molex 39-28-1063

Greenlee / A Textron Company 24 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

VCC

GREEN LED

HCPL4502

654321

TO I/O

Molex 39-28-1063

UF1001DI

R19

.0047uF/500VAC

PN2222A

R21

GROUND

NEUTRAL

LINE

321

AC POWER IN

Beau 72503-C

Page 25

853 Quad Bender™

Power Generation Unit Parts List (500 8357.0)

C1,C9,C10,C12,C13 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 5

AVX SA115C104KAA KEMET C420C104K5R5CA

C2 WIMA MKS21.06310 Capacitor, Film, 1 uF, 63 volts 1 C3 Philips A103M15Z5UFVVWA Capacitor, .01 uF, 50 volts 1

C4,C11 Sprague 440LS10 Capacitor, .010 uF, 500 volts AC 2 C5,C8 Sprague 440LD47 Capacitor, .0047 uF, 500 volts AC 2 C6 Panasonic ECE-S2EU102Z Capacitor, 1000 uF, 250 volts 1

C7 Panasonic EEU-FC1E681 Capacitor, 680 uF, 25 volts 1 D1 Panasonic LN48YP LED, T1, Amber 1

D2 Panasonic LN28RP LED, T1, Red 1

D3,D10 Motorola 1N5245B Zener Diode, 15 volts, 500 milliwatts 2 D4,D11 Panasonic LN38GP LED, T1, Green 2

D5,D6,D7 Generic 1N4148 Diode 3 D8 IXYS DSEI 30-06A Diode, Fast Recovery, 30A, 400-600V, TO-247 (see Note 1) 1

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 39-29-0023 Connector, Minifit Jr., 2-position, Gold 1 J5,J6,J8,J9,J10,J11 Keystone 1287 Connector, Tab, .250 x .032 6

J7 Beau 72503-C Connector, Terminal Block, 3-position, No Mount Holes 1

L1 Renco RL-1328-22-470 Choke, Common Mode 1 Q1 IXYS IXFK73N30 MOSFET, N channel, 73-76A, 300V, TO-264 (see Note 2) 1

Q2 Generic PN2222A Transistor, NPN 1 R1,R8 Generic Resistor, 2 kΩ, 1/4 watt, 5% 2 R2,R3,R12,R14 Generic Resistor, 1 MΩ, 1/4 watt, 5% 4 R4 Generic Resistor, 150 kΩ, 1/4 watt, 5% 1 R5 Generic Resistor, 12.1 kΩ, 1/4 watt, 1% 1 R6 Generic Resistor, 4.75 kΩ, 1/4 watt, 1% 1 R7,R24 Generic Resistor, 20 kΩ, 1/4 watt, 1% 2 R9,R11 Generic Resistor, 22 Ω, 1/4 watt, 5% 2 R10,R13 Generic Resistor, 100 kΩ, 1/4 watt, 5% 2 R15 Dale LVR-5 .04W Resistor, .040 Ω, 5 watt, 1% 1

R16,R23,R25 Generic Resistor, 10 kΩ, 1/4 watt, 1% 3 R17 Dale CW-10 4.7K Resistor, 4.7 kΩ, 10 watt, 5% (see Note 3) 1

R18 Dale RS-2B-20K Resistor, 20 kΩ, 2 watt, 1% 1

AVX SA105E103ZAA

Cornell Dubilier 380LX102M250K052

Liteon LTL-4251

Liteon LTL-4221

Liteon LTL-4231

Adv Pwr Tech APT30D40B Adv Pwr Tech APT30D60B

Magnum A202203

Adv Pwr Tech APT30M40LVFR

KRL NP-5A .04W Riedon MT-5 .04W

KRL C-10A 4.7K Riedon UT-10 4.7K

KRL C-2A 20K Riedon UT-2B 20K

Greenlee / A Textron Company 25 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 26

853 Quad Bender™

Power Generation Unit Parts List (500 8357.0) (cont’d)

R19,R21 Generic Resistor, 1 kΩ, 1/4 watt, 5% 2

R20 Generic Resistor, 1.5 MΩ, 1/4 watt, 5% 1 R22 Generic Resistor, 100 Ω, 1/4 watt, 1% 1 R26,R28 Generic Resistor, 1.5 kΩ, 1/4 watt, 1% 2 R27 Generic Resistor, 18.7 kΩ, 1/4 watt, 1% 1 R29 Generic Resistor, 68.1 kΩ, 1/4 watt, 1% 1

S1 Panasonic EVQ-PAC09K 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 HCPL4502 Siemens 6N136

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 .25" off-board .

Greenlee / A Textron Company 26 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 27

Layout Diagram — Power Generation Unit (500 8357.0)

853 Quad Bender™

TO I/OGround Neutral Line

654

321

C10

R13

R12

C3C1C9

R14

R25 R19

RedBlack

J10J11

TO RELAY

R16

R21

R24

R10

R28

R27

R15

321

PWM

TEST

R26

R23

C12

C13

R22

654

D10

D11

POWER

DIR

R11

R18

VCC

R17

Red Black

D14

C11

R20

D13

YellowYellow

FROM RECTIFIER

Greenlee / A Textron Company 27 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 28

USA 800-435-0786 Fax: 800-451-2632 815-397-7070 Fax: 815-397-1865 Canada 800-435-0786 Fax: 800-524-2853 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

www.greenlee.com

•

Greenlee Textron Inc. is a subsidiary of Textron Inc.

Printed in USA