854 Quad Bender INSTRUCTION MANUAL. Beginning with Serial Number ABT0000

Transcription

1 INSTRUCTION MANUAL 854 Quad Bender Beginning with Serial Number ABT0000 Read and understand all of the instructions and safety information in this manual before operating or servicing this tool Greenlee Textron Inc. IM 0 REV 0/07

2 Table of Contents Description... Safety... Purpose... Important Safety Information... 4 Grounding Instructions... 5 Identification... 6 Specifications... 6 Transportation and Setup... 7 Operation Illustrated Bending Glossary... 0 Bending Instructions... Special Bending Information... 0 Maintenance... Troubleshooting Exploded Views, Parts Lists, Schematics and Wiring Diagrams 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 of this Manual This manual is intended to familiarize personnel with the safe operation and maintenance procedures for the following tool: 854 (006) Serial Number ABT0000 Keep this manual available to all personnel. Replacement manuals are available upon request at no charge at Description The Greenlee 854 Quad Bender is an electric-powered conduit and pipe bender, intended to make up to 90 bends in /" to " conduit and pipe. It is capable of bending the following: EMT IMC Rigid Aluminum Rigid Steel 40 Mil PVC-Coated Rigid Steel (requires PVC Shoe Group 0700, purchased separately) Schedule 40 Pipe Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 5 of the Federal Communications Commission rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense. Do not make any modifications to this device. Unauthorized changes or modifications will void the user s authority to operate this device under United States federal law. KEEP THIS MANUAL All specifications 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. Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

3 IMPORTANT SAFETY INFORMATION 854 Quad Bender 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. Electric shock hazard: Connect the power cord to a 0 volt, 0 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. 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. Do not expose to rain. Do not use in wet or damp locations. Do not immerse the pendant switch in water or any other liquid. Failure to observe these warnings could result in severe injury or death. 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. 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 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 remove guards. Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

4 IMPORTANT SAFETY INFORMATION 854 Quad Bender Extension cords: Use only three-wire, -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 0 m (00'). 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. Inspect the bender before each use. Replace worn, damaged, or missing parts with Greenlee replacement parts. A damaged or improperly assembled component could break and strike nearby personnel. Do not overbend the conduit or pipe. Overbending could cause a hook to collide with the conduit or pipe, resulting in damage to the bender. Conduit moves rapidly as it is bent. Before starting a bend, remove any obstructions from the path of the conduit. Some of the components and accessories are heavy and may require two people to lift and assemble. Use this tool for the manufacturer s intended purpose only. Failure to observe these precautions may result in injury or property damage. Note: Keep all decals clean and legible, and replace when necessary. Unplug the bender before changing accessories. Accidental start-up could result in serious injury. Do not operate the bender while wearing loose clothing. Loose clothing can get caught in moving parts. Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

5 Grounding Instructions Electric shock hazard: Do not modify the plug provided with the tool. Connect this tool to a grounded receptacle on a 0 amp GFCIprotected circuit. Failure to observe these warnings could result in severe injury or death. This tool must be grounded. In the event of a malfunction or breakdown, an electrical ground provides a path of least resistance for the electric current. This path of least resistance is intended to reduce the risk of electric shock. This tool s electric cord has a grounding conductor and a grounding plug as shown. Do not modify the plug. Connect the plug to a corresponding GFCI protected receptacle that is properly installed and grounded in accordance with all national and local codes and ordinances. Do not use an adapter. 0 Amp/0 Volt Plug and Receptacle Plug Receptacle Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

6 Identification Conduit Bender. Bender Power Head. /" to -/4" Bending Shoe. On/Off Switch and Circuit Breaker 4. Bender Head Pivot Lock Knob 5. Lifting Eyes 6. Lockable Storage Area 7. Support Frame 8. Leveling Jack Screws 9. Support Roller Squeeze Adjustment 0. Support Roller Engagement Handle. -/" to " Roller Support System. -/" to " Bending Shoe. Shoe Retaining Lock Ring 4. Open Storage Area 5. Transport Handle Specifications Height...00 mm (47") Width...74 mm (8.5") Depth...90 mm (5.5") Mass/Weight (bender without shoes or roller supports)... kg (50 lb) Power Supply... 0 VAC, 0 amp GFCI-protected circuit Operating Conditions Temperature... 0 C to 49 C ( F to 0 F) Relative Humidity...0 to 98% Capacity... /" to " conduit and schedule 40 pipe Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

7 854 Quad Bender 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 95 mm (6") long to prevent contact with the bender. All lifting components must be rated for kg (50 lb).. Pivot the bending head to the horizontal position with the -/" to " shoe upward (see Pivoting the Bender Head in this section of the manual).. Rotate the lifting eyes so they are accessible.. 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:. Pull out the bender head pivot lock knob. It may be necessary to twist the knob clockwise until the pin clears the frame.. Pivot the bending head to the desired bending position.. 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. Lowering the Jack Screws The bender is equipped with four jack screws. To park the bender at the jobsite, use the 5/6" T-handle Allen wrench, which is shipped in the lockable storage area, to lower two of the jack screws. If desired, lower all four jack screws to level the bender. Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

8 Operation 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. Electric shock hazard: Connect the power cord to a 0 volt, 0 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. Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris. 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. Unplug the bender before changing accessories. Accidental start-up could result in serious injury. Do not operate the bender while wearing loose clothing. Loose clothing can get caught in moving parts. Failure to observe this warning could result in severe injury or death.. Mark the conduit. The decals on the bender and the Bending Instructions section of this manual provide basic instructions for marking and bending the conduit. They are based on measurements with common fractions for accurate results. For a higher level of precision, see the Special Bending Information section of this manual. This section is based on measurements carried out to two decimal places.. Turn the power switch/circuit breaker to ON.. Use the shoe selection switch on the side of the bender to select the proper shoe (/" to -4" shoe or -/" to " shoe). Press BEND or UNLOAD until the pointer of the selected shoe is 5 to 0 before the 0 starting point. 4. Insert the conduit into the proper shoe groove and hook (green hooks indicate IMC, rigid, and schedule 40 pipe; silver hooks indicate EMT). Load the conduit so that the bending mark is aligned with the front edge of the shoe hook. If bending /" to /4" conduit, use the roller support unit as explained under Operation. If bending -/" to " EMT, IMC or rigid aluminum, use the roller support unit and set the squeeze as explained under Operation. If bending -/" to " rigid steel conduit or schedule 40 pipe, ensure that the roller support unit is in the lowered position. 5. See the instruction decal or the Scale Reading Table for the appropriate bend angle. 6. Bend the conduit: a. Press and hold BEND. b. Release the BEND switch as you approach the desired angle of bend. c. Press BEND momentarily until the bend is complete. 7. Unload the bender. a. Press UNLOAD. The shoe will rotate back and drop the -/" to " roller support unit, if it was used. b. Twist the conduit to release it from the hook. Remove the conduit. c. Press and hold UNLOAD until the shoe has rotated back to 0. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

9 Operation (cont d) USING ROLLER SUPPORT UNITS Use the roller support units to squeeze the conduit as it is bent. Using the /" to -/4" Roller Support Unit Pivot this roller support upward and into place when bending all types of /" to -/4" conduit. Pivot the roller support down for easier loading and unloading. ADJUSTING THE SQUEEZE When bending -/" to " EMT, IMC, and rigid aluminum conduit, the roller support must be engaged so that the roller supports the conduit; the pressure against the conduit is the squeeze. Setting the squeeze adjustment arm to the vertical position (middle hole) provides the necessary amount of squeeze for most -/" to " EMT and IMC conduit. Using the -/" to " Roller Support Unit Engage this roller support when bending -/" to " EMT, IMC, and rigid aluminum conduit:. Load the conduit.. While momentarily pressing BEND, move the roller engagement handle up and to the left. The rollers will move up and squeeze the conduit against the shoe. Apply enough force so that the roller support unit contacts the stops before the conduit starts to bend. Note: If it is difficult to engage the rollers completely, the squeeze is probably set too high. See Adjusting the Squeeze in this section of the manual. Due to variations in conduit, the standard adjustment may provide too much or too little squeeze. If the conduit is difficult to load or develops excessive side marking when bent, the squeeze is set too high. If the conduit becomes excessively oval or wrinkled, the squeeze is set too low. To change the amount of squeeze:. Loosen the adjustment arm screw.. Rotate the adjustment arm one position counterclockwise to INCREASE the squeeze or one position clockwise to DECREASE the squeeze. Note: Decrease the squeeze by three settings when bending rigid aluminum conduit.. Align the adjustment arm with one of the holes and tighten the screw. Changing the squeeze may affect the bending accuracy. If the pointers are inaccurate after changing the squeeze, see Pointer Accuracy under Maintenance. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

10 Illustrated Bending Glossary back-to-back bend any U-shaped bend formed by two parallel 90 bends with a straight section of conduit or pipe between the bends. center-to-center distance the distance between the successive bends that make up an offset or a three-bend saddle. developed length the actual length of pipe that will be bent; see distance d in the illustration at left. r gain the difference between the straight-line distance (a + a) and the shorter radial distance, (d) where: a d a θ = angle of bend r = the centerline bending radius of the bending shoe kick single bend of less than 90 leg length the distance from the end of a straight section of conduit or pipe to the bend; measured from the end to the outside edge of the conduit or pipe. offset bend two opposite bends with the same degree of bend; used to avoid an obstruction. Offset Height offset height the distance between the two legs of an offset bend, measured perpendicular to the two legs; also called amount of offset and depth of offset. rise the distance from the end of a straight section of conduit or pipe to the bend; measured from the end to the center line of the conduit or pipe. Also called stub or stub-up. saddle a three-bend or four-bend combination; used to avoid an obstruction. shrink the amount of conduit lost when laying out an offset bend working toward an obstruction; see the explanation under Offset Bending in this manual. springback the amount, measured in degrees, that a conduit or pipe tends to straighten after being bent. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

11 Bending Instructions Single Bends (Stubs and Kicks). Measure the length of the required stub.. See the Minimum Stub on the Deduct Table. The required stub must be equal to or longer than the Minimum Stub.. Measure and mark the stub length on the conduit. This is the Stub Length Mark. Subtract the Deduct from this mark and make a new mark. This is Bending Mark. 4. Align Bending Mark with the front edge of the hook and bend the conduit. Note: When the operator presses UNLOAD, the conduit may spring back a few degrees. Compensate by overbending as shown in the Scale Reading Table. STUB LENGTH STUB LENGTH MARK Deduct Table Conduit Size Deduct EMT Miminum Stub Deduct IMC/Rigid Minimum Stub /" 7-/ 9-/ 7-/ 9-/ /4" 9 9 " -/4" -5/8 5-5/8-5/8 5-5/8 -/" 4-7/8 6-7/8 4-7/8 6-7/8 BENDING MARK STUB LENGTH DEDUCT BENDING MARK STUB LENGTH MARK " 6-/8 8-/8 6-/8 8-/8 Scale Reading Table Conduit Size Conduit Type Start (0 ) 5 -/ EMT 6-/ 4 -/ 46-/ 6-/ 9-/ IMC -/ 7-/ 5-/ 48 6-/ 9-/ /" RIG 6-/ 4 -/ 46-/ 6-/ 9-/ AL 6 -/ 46-/ 6-/ 9-/ PVC -/ 6-/ 4 -/ 46-/ 6-/ 9-/ EMT 6 4 -/ 46-/ 6 9-/ IMC 6-/ 4 -/ / /4" RIG / 5-/ 0-/ 45-/ 60-/ 90-/ AL / 5-/ -/ 46 6-/ 9 PVC 0 5 -/ EMT 0 5 -/ 0 45-/ 60-/ 90-/ IMC 7 4-/ / " RIG 6 -/ AL / 5-/ -/ 46 6-/ 9-/ PVC / 5-/ 0-/ 45-/ 60-/ 90-/ EMT 6 -/ -/ 46-/ 6-/ 9 IMC 7-/ 5 -/ 47-/ 6-/ 9-/ -/4" RIG 6 -/ / 90-/ AL -/ 6-/ 4 -/ 46-/ 6-/ 9-/ PVC / 5-/ 0-/ 45-/ 60-/ 90-/ EMT 6 4 -/ 46-/ 6-/ 9 IMC 7 5 -/ 47-/ 6 9-/ -/" RIG 0 5 -/ / AL 6 -/ 46 6-/ 9-/ PVC / 6 -/ EMT / 5 -/ / 89 IMC -/ 8-/ 6 -/ 48-/ 6-/ 94 " RIG 6 -/ 45-/ 60-/ 90-/ AL 7 4-/ 47 6-/ 9-/ PVC 7 4-/ -/ 46-/ 6-/ 9-/ Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

12 Bending Instructions (cont d) Offsets. Measure the height and length of the obstruction. Select the angle to be used. START OF BEND BENDING MARK. Refer to the X Table for the X dimension, and refer to the Offset Table for the centerto-center distance. BENDING MARK X CENTER TO CENTER Note: If the center-to-center distance is not shown, calculate it by using the multipliers shown in the Offset Table.. Mark the conduit as shown. 4. Insert the conduit into the bender. Align Bending Mark with the front edge of the hook and bend the conduit. START OF BEND X 5. Without removing the conduit from the bender, align Bending Mark with the front edge of the hook and rotate the conduit 80. Make the second bend. BENDING MARK CEN TER TO CENTER BENDING MARK X Table Conduit Size X /" -/ /4" -/6 " -/6 -/4" 4 -/" 4-/4 " 4-/4 Offset Table Offset Maximum Conduit Size Finished Angle Centerto-center /4 7-/4 Maximum Conduit Size Centerto-center 4 -/ 5-7/6 /4 7-5/6 Maximum Conduit Size Centerto-center 6 -/6-5/6 / 8-5/ /8 -/ 5-5/6 -/ /8 9-5/6 -/4 -/6 46-/8-5/6 -/ 6-5/ /6 7-5/6 9-7/6 6 6-/6-5/6 -/ /6 5-5/6 5-/ /4 9-5/6 7-5/ /6 0-/4 Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

13 Special Bending Information The Special Bending Information section and the Special Bending Information Chart are used together for making very precise bends. The Special Bending Information Chart is divided into sections by the size and type of conduit. Each section contains dimensions (such as Y, L, L, and Z) that correspond to the illustrations. The top row of the Special Bending Information Chart shows some of the typical heights (", 4", 6", etc), which correspond to the heights in the illustrations. SINGLE BENDS (Stubs and Kicks). Select the size and type of conduit. Determine the height of the stub or kick and the angle to be used.. Find the corresponding section of the Special Bending Information Chart.. In the row at the top of the page, find the height of the stub. Under the height, find the corresponding Y dimension. 4. Mark the conduit as shown. Bend the conduit. 4. In the row at the top of the page, find the height of the obstruction. Under the height, find the corresponding L dimension. 5. Mark the conduit as shown. Bend the conduit. HEIGHT Note: After the first bend, do not remove the conduit from the bender. Advance the conduit until the second bending mark is aligned with the front edge of the hook, rotate the conduit 80, and make the second bend. LENGTH LENGTH X START OF FIRST BEND ANGLE L HEIGHT BENDING MARK BENDING MARK OFFSETS Y ANGLE MARK An offset is used to route the conduit around an obstruction. To make an offset, two equal bends are required. The distance between the two bends is the center-to-center distance. When working past an obstruction, it is necessary to determine the location of the first bend. The center-tocenter distance is then used to measure and mark the distance to the second bend. When working toward an obstruction, it is necessary to determine the location of the second bend. The centerto-center distance is then used to measure and mark the distance to the first bend. Offsets Working Toward an Obstruction. Select the size and type of conduit. Measure the height of the obstruction and the distance labeled LENGTH TO END OF SECOND BEND. Determine the angle to be used.. Find the corresponding section of the Special Bending Information Chart.. In the row at the top of the page, find the height of the obstruction. Under the height, find the corresponding L and Z dimensions. 4. Mark the conduit as shown. Bend the conduit. Note: After the first bend, do not remove the conduit from the bender. Advance the conduit until the second bending mark is aligned with the front edge of the hook, rotate the conduit 80, and make the second bend. LENGTH TO END OF SECOND BEND Offsets Working Past an Obstruction. Select the size and type of conduit. Measure the height of the obstruction and the distance labeled LENGTH. Determine the angle to be used.. Find the X dimension in the X Table under Bending Instructions. Subtract X from the LENGTH and mark the conduit, as shown.. Find the corresponding section of the Special Bending Information Chart. HEIGHT LENGTH Z BENDING MARK ANGLE L BENDING MARK Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

14 Special Bending Information (cont d) THREE-BEND SADDLE A three-bend saddle is used to route the conduit around an obstruction. To make a three-bend saddle, three bends are required; the first and third bends are an equal number of degrees; the second bend is twice that number of degrees.. Select the size and type of conduit. Measure the height of the obstruction and the distance labeled LENGTH TO CENTER. Determine the angle to be used. Note: The angle to be used is the first and third angle of the saddle (not the second), as illustrated. Refer to this angle when looking up the corresponding information in the Special Bending Information Chart.. Find the corresponding section of the Special Bending Information Chart.. In the row at the top of the page, find the height of the obstruction. Under the height, find the corresponding L, L and Z dimensions. 4. Mark the conduit as shown. Bend the conduit. Note: After the first bend, do not remove the conduit from the bender. Advance the conduit until the second bending mark is aligned with the front edge of the hook, rotate the conduit 80, and make the second bend. Then advance the conduit to the third bending mark, rotate the conduit 80 again, and make the third bend. LENGTH TO CENTER HEIGHT ANGLE FOUR-BEND SADDLE. Select the size and type of conduit. Measure the distances labeled LENGTH, STRAIGHT SECTION, and HEIGHT. Determine the angle to be used.. Find the corresponding section of the Special Bending Information Chart.. In the row at the top of the page, find the height of the obstruction. Under the height, find the corresponding L, L and Z dimensions. 4. Mark the conduit as shown. Bend the conduit. LENGTH Z L L U-BENDS LENGTH BENDING MARK BENDING MARK STRAIGHT SECTION HEIGHT L + STRAIGHT SECTION ANGLE BENDING MARK BENDING MARK 4. Select the size and type of conduit. Measure and mark the distances labeled HEIGHT and LENGTH.. Find the corresponding section of the Special Bending Information Chart.. In the row at the top of the page, find the height of the illustration. Under the height, find the corresponding L and Y dimensions. 4. Mark the conduit as shown. Bend the conduit. LENGTH LENGTH Z L L BENDING MARK BENDING MARK BENDING MARK HEIGHT Y L BENDING MARK BENDING MARK Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

15 Special Bending Information Chart /" EMT MINIMUM H = 0.95 MINIMUM H =.6 MINIMUM H =.44 MINIMUM H = 4.7 MINIMUM H = 6.6 MINIMUM H =.8 /4" EMT MINIMUM H =.0 MINIMUM H =.06 MINIMUM H =.08 MINIMUM H = 5.5 MINIMUM H = 8.8 MINIMUM H= 4.47 DIM ANGLE " 4" 6" 8" 0" " 5" 8" 4" 6" Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

16 Special Bending Information Chart (cont d) DIM ANGLE " 4" 6" 8" 0" " 5" 8" 4" 6" " EMT MINIMUM H =. MINIMUM H =. MINIMUM H =.5 MINIMUM H = 6.48 MINIMUM H = 9.97 MINIMUM H = 7.6 -/4" EMT MINIMUM H =.65 MINIMUM H =.89 MINIMUM H = 4.40 MINIMUM H = 8.0 MINIMUM H =.49 MINIMUM H =.0 Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

17 Special Bending Information Chart (cont d) DIM ANGLE " 4" 6" 8" 0" " 5" 8" 4" 6" -/" EMT MINIMUM H =.99 MINIMUM H =.40 MINIMUM H = 5.05 MINIMUM H = 8.96 MINIMUM H =.46 MINIMUM H =.00 " EMT MINIMUM H =.09 MINIMUM H =.59 MINIMUM H = 5.7 MINIMUM H = 9.6 MINIMUM H = 4.54 MINIMUM H= 5.06 Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

18 Special Bending Information Chart (cont d) DIM ANGLE " 4" 6" 8" 0" " 5" 8" 4" 6" /" IMC/Rigid MINIMUM H = 0.95 MINIMUM H =.6 MINIMUM H =.4 MINIMUM H = 4. MINIMUM H = 6.55 MINIMUM H =.6 /4" IMC/Rigid MINIMUM H =.9 MINIMUM H =.05 MINIMUM H =.06 MINIMUM H = 5.49 MINIMUM H = 8. MINIMUM H = 4. Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

19 Special Bending Information Chart (cont d) DIM ANGLE " 4" 6" 8" 0" " 5" 8" 4" 6" " IMC/Rigid MINIMUM H =. MINIMUM H =. MINIMUM H =.5 MINIMUM H = 6.44 MINIMUM H = 9.9 MINIMUM H = /4" IMC/Rigid MINIMUM H =.6 MINIMUM H =.88 MINIMUM H = 4.8 MINIMUM H = 8.06 MINIMUM H =.4 MINIMUM H =.96 Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

20 Special Bending Information Chart (cont d) DIM ANGLE " 4" 6" 8" 0" " 5" 8" 4" 6" -/" IMC/Rigid MINIMUM H =.97 MINIMUM H =.6 MINIMUM H = 4.98 MINIMUM H = 8.8 MINIMUM H =. MINIMUM H =.50 " IMC/Rigid MINIMUM H =.06 MINIMUM H =.5 MINIMUM H = 5.6 MINIMUM H = 9.8 MINIMUM H = 4.4 MINIMUM H = 4.5 Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Y L L Z Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

21 Maintenance Schedule 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 flying debris. Component Maintenance Activity Maintenance Interval Chain Roller Supports Commutator Brushes Lubrication and Tension Adjustment Cleaning and Lubrication Replacement Every 6 months* Every 6 months* When drive unit performance diminishes noticeably * More often if the bender is used in dusty or corrosive environments Chain Lubrication and Tension Adjustment. Disconnect the bender from the power source.. See the -/" to " Side Exploded View. Remove the -/" to " shoe (see Changing Shoes in this section of the manual).. See the Main Exploded View. Remove the screws () 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 5 mm ("), proceed to step 6. Less than 5 mm ("), proceed to step Remove screws () and motor guard (5). 7. Loosen the two motor mounting screws (5) on the front, and the two on the back, and the nut (). 8. Torque the eccentric locator () to 8 Nm (60 ft-lb). Maintain this amount of torque while tightening the nut () and two front screws (5). 9. Tighten the two rear screws (5). 0. Assemble in reverse order. /" to -/4" Roller Support. Disconnect the bender from the power source.. Remove support pivot pin (9). Remove roller support (7).. Spray a motorcycle chain lubricant through the mm (/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. Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

22 Maintenance (cont d) -/" to " Roller Support. Disconnect the bender from the power source.. Remove the -/" to " shoe (see Changing Shoes in this section of the manual).. See the -/" to " Roller Support Unit Exploded View. Use a pair of needlenose pliers to disconnect the springs (04) 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 (9). 6. Place one hand under the support arms (7) to support the weight of the roller support unit. Remove the eccentric shaft (9). 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 could result in injury or property damage. 7. Lift the roller support subassembly to the left and upward. 8. On the -/" roller group: Loosen the sleeve set screw (98) and remove the -/" pivot roller shaft (86) with grip (90). Remove the sleeve (87). Remove two hex head screws (9). Remove the outer roller plate (75). Remove the tail roller (84). Remove all components of the split roller assembly. 9. On the " roller group: Loosen the sleeve set screw (98) and press out the " pivot shaft (88). Remove the sleeve (89). Remove the hex head screw (9). Remove one retaining ring (95) from the tail roller shaft (8). Remove outer roller plate (76). Remove the tail roller (8) and center roller (85). Remove all components of the split roller assembly. 0. Clean off all of the grease and dirt.. Inspect each item. Replace any worn, damaged, or missing items.. Lubricate all working surfaces with a high-quality grease.. 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 " roller group only: After replacing any split roller components, add or remove shim washers (99, 9, or 50) as needed. On the -/" roller group: Install the two belleville washers (00) so that the inside diameters contact each other. Use Loctite 7 on the two hex head screws (9). Torque to 55 to 6 Nm (40 to 45 ft-lb). 4. Position the roller support arms (7) as shown. Assemble the roller groups to the support arms. 5. 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 (07). 6. Insert the eccentric shaft (9). Note: You may need to rotate the eccentric shaft to get it to seat completely. 7. Install the adapter sleeve (9) and three button head cap screws (96). 8. Install the adjustment arm (74) and adjustment arm screw (97). 9. Attach the springs (04) to the holes in the side of the bender frame beneath the roller support unit. 0. Put the bender in the horizontal bending position. Adjust the set screw (07), if necessary, so that the support arms (7) are centered between the front and back plates. Engage and disengage the roller support unit to be sure that it moves freely. Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

23 Maintenance (cont d) Changing Shoes. Disconnect the bender from the power source.. Lock the bender head in the vertical bending position (see Pivoting the Bender Head in the Transportation and Setup section of this manual).. See the /" to -/4" Side Exploded View or the -/" to " Side Exploded View. Use retaining ring pliers to remove the retaining ring (6) that secures the shoe. 4. Remove the shoe from the spindle. Pointer Accuracy. Loosen the two locking screws (9).. Move the pointer (0 or ).. Tighten the screws. Locking Screws Drive lugs closest to hooks must engage in these holes. Protruding Bolts Commutator Brushes. Disconnect the bender from the power source.. See the Main Exploded View. Remove the screws () and the motor guard (5). Remove the motor guard.. Remove the power cord strain relief (7). 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 () to release it. Unplug the brush and remove it. Replace the brush if it is less than 6 mm (/4") long. 6. Repeat step 5 for the other brush. 7. Assemble in reverse order. 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. Greenlee / A Textron Company 4455 Boeing Dr. Rockford, IL USA

24 Troubleshooting Problem Probable Cause Probable Remedy Bender will not operate. No voltage. Check supply voltage circuit operation. Check that switch is ON. Bender operates in wrong direction. Wrong side of bender selected. Set selector switch properly. Bends are overbent a few degrees. Pointer is adjusted wrong. Loosen pointer locking screws and rotate clockwise to compensate. Retighten locking screws. Too much squeeze on -/" or " EMT or IMC conduit. Unusual conduit characteristics. Back squeeze off per adjustment instructions. 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 -/" or " EMT or IMC conduit. Unusual conduit characteristics. Increase squeeze per adjustment instructions. Adjust pointer or bend to a larger angle to compensate. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

25 Troubleshooting (cont d) The following flow charts show the suggested troubleshooting procedures for some bender problems. They by no means encompass all possible problems or solutions. 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. YES 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. Is the current on the 5 VAC line exceeding 0 amps? YES Is the DC current to the motor exceeding 7 amps? NO When BEND is pressed, is the voltage sent to the motor 0 to 50 volts over the AC line voltage? YES Are connectors corroded? NO NO YES NO YES Replace circuit breaker. Replace motor. Replace bridge rectifier ( ). Clean. Replace PGU. Won t bend Is 5 VAC measured at PGU board input? NO Plugged into dead circuit, bad power cord, or switch is bad or off. Won t stop Is the supply line voltage low? NO YES Use 5 VAC. YES Does the green LED on the I/O board light? NO Replace transformer unit. Does bender stop when the pendant is unplugged? NO YES Replace pendant switch. YES Replace PGU. Are metal oxide varistors (MOVs) on PGU board damaged or discolored? NO YES Replace PGU. Bender only runs in one direction Does the green LED on the PGU light? YES Does amber or red LED on I/O light when BEND or UNLOAD is pressed? NO NO Replace PGU. Unplug pendant or I/O and check switch for continuity. If ok, replace I/O. On 854 move pendant plug to I/O board. Does bender run both directions? NO Does amber or red LED light when switch is pressed? YES NO Replace direction switch assembly. Check and replace pendant switch. YES Does relay on I/O operate when BEND or UNLOAD is pressed? YES NO Replace I/O. YES When amber or red LED is on, is VDC measured at large relay coil on PGU (where relay wire unit connects)? NO Replace PGU. Replace PGU. YES Replace relay. Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

26 /" to -/4" Side Exploded View Shoe Unit /" to -/4" consists of,,, 4 and Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

27 -/" to " Side Exploded View The Roller Support Unit exploded view is on the following page. 44 Shoe Unit -/" to " consists of 4, 6, 7, 8 and Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

28 -/" to " Roller Support Unit Exploded View and Parts List * 9* , 9 or 50 9* Torque to 94 Nm (70 ft-lb) Roller Support Unit consists of: UPC No. Key Part No. Description Qty Support weldment, roller Support weldment, -/" Support weldment, " Arm weldment, adjustment Plate, -/" outer roller Plate, " outer roller Split rollers, -/" Ball, -/" Split rollers, " Ball, " Spacer, " roller Roller unit, " Shaft, " rear roller Roller, -/" IMC Roller, " tail Shaft, -/" pivot roller Sleeve, -/" Shaft, " pivot Sleeve, " Grip... UPC No. Key Part No. Description Qty Shaft, eccentric Sleeve adapter Screw, 7/6-4 x.00 hex head Shaft, -/" Support Retaining ring # Screw, cap /4-0 x.7 button head Screw, 5/6-8 x.00 socket head Screw, /4-8 x.5 set Washer,.00 x.7 x.0 shim Washer, Belleville.6 x Washer,.6 x.00 x.06 flat Spring, extension.75 x Clamp, loop-type Guide, spring O-ring,.50 x.6 x O-ring,.75 x.87 x Shaft, middle roller Washer, / shim Washer, /6 shim Retaining ring # Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

29 Drive Unit Exploded View and Parts List A Bolt Tightening Sequence for Gearbox Cover 6. Torque gearbox bolts to /9 Nm (00/80 in-lb) in sequence shown.. Assemble all Belleville washers so that I.D. s butt and O.D. s contact bearings.. Tighten motor nuts (4) to /4 Nm (0/5 in-lb). 4. Insert commutator brushes before connecting push-on terminals UPC No. Key Part No. Description Commutator brushes Commutator brush retension springs Tail housing Brush assembly plate Cord Shroud Armature/housing set 8A Bearing Belleville washers Rear gear housing Gasket Front gear housing Output gear shaft Short spacer Long spacer nd Reduction pinion shaft w/ BRGs Wave washer rd Reduction pinion shaft w/ BRGs Belleville washer th Reduction pinion shaft Small spacer /-0 x -/ Screw /4-8 x 9-/4" Stud /4-8 Hex nut /4" Internal tooth lockwasher Greenlee / A Textron Company Boeing Dr. Rockford, IL USA