Textron Greenlee 854DX Service Manual
SERVICE MANUAL
854DX
Electric Bender
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
52067682 © 2014 Greenlee Textron Inc. 5/14
854DX Electric Bender
Table of Contents
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Other Publications ......................................................... 2
Important Safety Information .....................................3–5
Service Instructions ..................................................6–14
Illustrations .............................................................15–17
Parts List ................................................................18–23
Bending Attachments .............................................24–25
Wiring Diagram ............................................................ 26
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This 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 of this Manual
This manual is intended to familiarize authorized
Greenlee service center personnel with the safe
operation and maintenance procedures for the
Greenlee˛854DX Electric Bender.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge at www.greenlee.com.
Other Publications
Instruction Manual: Publication 52067681
Do not discard this product or throw away!
For recycling information, go to www.greenlee.com.
All specications 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.
KEEP THIS MANUAL
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
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, dened 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.
854DX Electric Bender
Electric shock hazard:
• Inspect the power cord before
use. Repair or replace the cord if
damaged.
• Connect the power cord to a
120 volt, 20 amp receptacle on a
ground fault protected circuit only.
Refer to “Grounding Instructions.”
• Do not modify the power cord or
plug.
• Disconnect the unit 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. Refer also to the
Instruction Manual, which is listed
under “Other Publications.”
Failure to observe this warning will
result in severe injury or death.
Do not use this tool in a hazardous
environment. Hazards include ammable liquids, gases, or other materials. Using this tool in a hazardous
environment can result in a re or
explosion.
Failure to observe this warning will
result in severe injury or death.
For continued protection against risk of re and
electric shock, replace ONLY with same manufacturer,
type, and rating of fuse. Refer to the “Maintenance”
section of the Instruction Manual, which is listed
under “Other Publications.”
Failure to observe this warning could result in severe
injury or death.
• Do not use in dangerous environment. Do not use power tools in
damp or wet locations, or expose
them to rain. Keep work area well
lighted.
• Do not immerse the pendant switch
in water or any other liquid.
Failure to observe these warnings
could result in severe injury or death.
Always use safety glasses. Everyday
glasses only have impact resistant
lenses; they are NOT safety glasses.
When using in dusty environment, use
face or dust mask.
Failure to wear eye protection could
result in serious eye injury from ying
debris.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
854DX Electric Bender
IMPORTANT SAFETY INFORMATION
• Keep guards in place and in
working order.
• Remove any tools from bender
before operating. Form habit of
checking to see that all tools are
removed from bender before
turning it on.
Failure to observe these warnings
could result in severe injury or death.
Extension cords:
• Use only three-wire, 12 AWG extension cords that have three-prong
grounding-type plugs and threehole 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.
• Support conduit when unloading.
Conduit can become loose and fall
if not properly supported.
Failure to observe these warnings
could result in severe injury or death.
• Reduce the risk of unintentional starting. Make sure
switch is in off position before plugging in.
• Never leave tool running unattended. Turn power
off. Do not leave tool until it comes to a complete
stop.
• Disconnect tools before servicing and when changing accessories such as shoes, rollers, and the like.
Accidental start-up could result in serious injury.
Failure to observe these warnings could result in
severe injury or death.
• Never stand on tool. Serious injury could occur if
the tool is tipped.
• Do not overreach. Keep proper footing and balance
at all times.
Failure to observe these warnings could result in
severe injury or death.
Adjust fork spacing to match fork tubes on bender.
Ensure front wheel brakes are engaged before inserting forks into fork tubes.
Failure to observe this warning could result in severe
injury or death.
• Select the appropriate shoe groove and support
roller for the type and size of conduit before
bending.
• Do not bend conduit over 96 degrees. Overbending
could result in the other shoe hook colliding with
the conduit.
Failure to observe these precautions may result in
injury or property damage.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
854DX Electric Bender
IMPORTANT SAFETY INFORMATION
• 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.
• Wear proper apparel. Do not wear loose clothing,
gloves, neckties, rings, bracelets, or other jewelry
which may get caught in moving parts. Nonslip
footwear is recommended. Wear protective hair
covering to contain long hair.
• Do not force rollers or alter tool. It will do the
job better and safer at the rate for which it was
designed.
• Use right tool. Do not force tool or attachment to do
a job for which it was not designed.
• 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 may result in
injury or property damage.
• Keep work area clean. Cluttered areas and benches
invite accidents.
• Keep children away. All visitors should be kept safe
distance from work area.
• Make workshop kid proof with padlocks, master
switches, or by removing starter keys.
Failure to observe these precautions may result in
injury or property damage.
• 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.
• Maintain tools with care. Keep tool clean for best
and safest performance. Follow instructions for
lubricating and changing accessories.
• Check damaged parts. Before further use of the
tool, a guard or other part that is damaged should
be carefully checked to determine that it will
operate properly and perform its intended function. Check for alignment of moving parts, binding
of moving parts, breakage of parts, mounting, and
any other conditions that may affect its operation.
A guard or other part that is damaged should be
properly repaired or replaced.
• Use recommended accessories. Consult the
instruction manual for recommended accessories.
The use of improper accessories may cause risk of
injury to persons.
• Some bender parts and accessories are heavy
and may require more than one person to lift and
assemble.
Failure to observe these precautions may result in
injury or property damage.
Note: Keep all decals clean and legible, and replace
when necessary.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Service Instructions
854DX Electric Bender
Roller Assembly Removal
1. Position the bender head in the vertical position.
2. Pull the ring of the lock pin in the shoe, and while
pulling the lock pin slide the shoe off the main
spindle.
3. Remove the detent pin and the 1/2" to 1" roller
support along with the lifting handle.
4. Disconnect the roller return spring from the roller
arm weldment.
5. Disconnect the spring from the 1-1/2" rollers group.
6. Slide the roller assembly and the roller support
assembly outward together about an inch until the
2" tail roller shaft is free from the slot in the roller
stop plate.
7. Remove the lock collar that retains the roller
assembly.
8. Rotate the roller assembly counterclockwise until
the roller plates are clear of the support plates.
9. Slide the roller assembly out to remove.
10. Reassemble in reverse order noting the following:
When sliding the roller assembly onto the support
shaft, keep the arm weldment between the 12 and
1o’clock position to prevent damaging the arm
position switch.
Roller Assembly Disassembly
1. Loosen the set screw on the collar that secures the
roller engagement handle, and pull out the handle,
1-1/4" roller group, and 1-1/2" roller group.
2. Loosen the set screw on the cam release mechanism, pull or drive out the pivot shaft, and remove
the 2" roller group.
3. Disassemble the 1-1/4" roller group.
a. Remove the two hex screws securing the outer
plate and the outer plate.
b. Remove the two rollers.
c. Reassemble in reverse order noting the
following:
• The slightly larger diameter roller mounts to
the left.
• Apply molybdenum grease to the roller shafts.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Service Instructions (cont’d)
4. Disassemble the 1-1/2" roller group.
a. Remove the two hex screws securing the outer
plate and the outer plate.
b. Remove the tail roller.
c. Remove the O-rings, pivot balls, split rollers, and
belleville washers noting their orientation.
d. Reassemble in reverse order noting the
following:
• Assemble the Belleville washers so they form a
“V” open outward.
• Place the O-rings between the split rollers until
both screws have been tightened and then slip
them over the split rollers so they form a seal
between the rollers and the pivot ball.
• Apply molybdenum grease to the tail roller
shaft and pivot balls.
5. Disassemble the 2" roller group.
a. Remove the hex screw, retaining ring, and outer
plate.
b. Remove the middle roller, middle shaft, tail roller,
and tail shaft.
c. Remove the O-rings, pivot balls, split rollers, and
spacer.
d. Reassemble in reverse order noting the
following:
• Place the O-rings between the split rollers until
the screw has been tightened and then slip
them over the split rollers so they form a seal
between the rollers and the pivot ball.
• Apply molybdenum grease to the middle roller
shaft and pivot balls.
6. Reassemble the full assembly in reverse order
noting the following:
a. The end of the 2" pivot shaft should be ush
outside of the adjacent arm.
b. The end of the engagement handle should be
ush with the inside of the same arm.
c. The cam release mechanism should be installed
with the spring on the inboard side of the lever.
d. The tail of the 1-1/4" roller group must be
trapped below the tail of the 1-1/2" roller group.
854DX Electric Bender
Roller Support Assembly Removal
1. Remove the roller assembly (refer to previous
instruction).
2. Slide the roller support assembly off the frame
tubes.
3. Reassemble in reverse order noting the following:
Fit the spring retainer with the two springs over the
lower frame tube between the second and third
support plates (as counted from the outside).
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Service Instructions (cont’d)
854DX Electric Bender
Roller Support Assembly Disassembly
1. Remove the two hex nuts securing all the support
plates.
2. Remove the rst plate and two short spacers.
3. Pry the plate from the rollpin, and remove the
second plate and two long spacers.
4. Remove the third plate and two long spacers.
5. Pry the plate from the rollpin, and remove the fourth
plate and two long spacers.
6. Remove the screws from the last support plate.
7. Reassemble in reverse order noting the following:
a. Slip joint pliers can be used to press the spring
anchor rollpins into the support plates by
squeezing the plates together over the rollpin.
b. Slide the completed assembly onto the frame
tubes with the nuts loose and tighten on the
frame to ease mounting and future removal.
c. With the assembly fully pushed in, the tip of the
right side 6" screw should t inside the hex head
of the 5/16" screw attached to the roller stop
plate.
Eccentric Roller Shaft
1. Remove the roller assembly (refer to previous
instruction).
2. Remove the ber thrust washer from the front of the
shaft.
3. Remove seven screws and rear chain guard.
4. Remove two screws securing squeeze adjuster and
the retainer on the top screw. Note which hole the
lower screw is in.
5. Remove the adjuster.
6. Remove the rollpins by driving them into the ID of
the shaft.
7. Pull out the shaft from the front and the rear eccentric from the rear.
8. Remove the front eccentric same as the rear if
needed.
9. Reassemble in reverse order noting the following:
a. Slide the front eccentric over the shaft so the
3/16" holes are closest to the rear.
b. Drive the rollpins into the holes so that they do
not protrude.
c. Lubricate the eccentrics with molybdenum
grease.
d. Insert the shaft into the frame from the front.
e. Insert the rear eccentric into the frame and over
the shaft so the 3/16" holes are visible.
f. Align the holes in the eccentric and shaft
together, making sure that thick part of both
eccentrics are oriented together.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
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