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SERVICE MANUAL

Read and understand all of the instructions andsafety information in this manual before operatingor servicing this tool.

999 3834.0 © 2005 Greenlee Textron Inc. SB 283 REV 4 2/05

854Quad Bender

Beginning with Serial Number ADT0000

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

854 Quad Bender

KEEP THIS MANUAL

SafetySafety is essential in the use and maintenance ofGreenlee tools and equipment. This instruction manualand any markings on the tool provide information foravoiding hazards and unsafe practices related to theuse of this tool. Observe all of the safety informationprovided.

PurposeThis manual is intended to familiarize authorizedGreenlee service center personnel with the safe opera-tion and maintenance procedures for the Greenlee 854Quad Bender, beginning with Serial Number ADT0000.

Keep this manual available to all personnel.

Replacement manuals are available upon request at nocharge.

The Greenlee 854 Quad Bender is protected byU.S. Patent No. 5,226,305.

Other PublicationsInstruction Manual: Publication 999 3729.8 (IM 1526)

Table of Contents

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

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

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

Important Safety Information ..................................... 3–4

Transportation and Setup .............................................. 5

Maintenance .............................................................. 6–9

Troubleshooting ..................................................... 10–11

Exploded Views and Parts Lists ............................ 12–19

Wiring Diagram ...................................................... 20–21

I/O Electrical Schematic ......................................... 22–23

PCB Layout .................................................................. 24

Power Generation Unit .......................................... 25–27

All specifications are nominal and may change as design improve-ments occur. Greenlee Textron Inc. shall not be liable for damagesresulting from misapplication or misuse of its products.

Loctite is a registered trademark of Loctite Corporation.

Molex is a registered trademark of Molex Inc.


854 Quad Bender

This symbol is used to call your attention tohazards or unsafe practices which could result inan injury or property damage. The signal word,defined below, indicates the severity of the hazard.The message after the signal word providesinformation for preventing or avoiding the hazard.

Hazards or unsafe practices which, if not avoided,MAY result in injury or property damage.

Hazards which, if not avoided, COULD result insevere injury or death.

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

SAFETYALERTSYMBOL

Read and understand all of theinstructions and safety informationin this manual before operating orservicing this tool.

Failure to observe this warning willresult in severe injury or death.

• Do not expose to rain.

• Do not use in wet or damplocations.

Failure to observe these warningscould result in severe injury or death.

Wear eye protection when operatingor servicing this tool.

Failure to wear eye protection couldresult in serious eye injury fromflying debris.

Do not remove guards.

Failure to observe this warningcould result in severe injury ordeath.Do not use this tool in a hazardous

environment. Hazards includeflammable liquids, gases, or othermaterials. Using this tool in ahazardous environment can result ina fire or explosion.

Failure to observe this warning willresult in severe injury or death.

IMPORTANT SAFETY INFORMATION

Electric shock hazard:

• Connect the power cord to a120 volt, 20 amp receptacle on aground fault protected circuit only.See Grounding Instructions.

• Do not modify the power cord orplug.

• Inspect the power cord before use.Repair or replace the cord ifdamaged.

• Disconnect from power beforeservicing.

Failure to observe this warning couldresult in severe injury or death.


854 Quad Bender

IMPORTANT SAFETY INFORMATION

• Conduit moves rapidly as it is bent. The path ofthe conduit must be clear of obstructions. Besure clearance is adequate before starting thebend.

• Do not operate the bender while wearing looseclothing. Loose clothing can get caught in movingparts.

• Inspect the bender before use. Replace worn,damaged or missing parts with Greenlee replace-ment parts. A damaged or improperly assembledcomponent could break and strike nearbypersonnel.

• Some bender parts and accessories are heavyand may require more than one person to lift andassemble.

• Use only accessories and attachments recom-mended by Greenlee.

• Do not stand on the bender; the bender may tipover.

• Do not leave the tool running unattended. Do notleave the tool until it comes to a complete stop.Turn the power off and unplug the tool after use.

• Ensure that all bystanders are away from thework area when operating the bender.

• Ensure that the work area is clean, dry,uncluttered, and well-lit.

• Use this tool for the manufacturer’s intendedpurpose only. Use other than that which isdescribed in this manual can result in injury orproperty damage.

Failure to observe these precautions may result ininjury or property damage.

Pinch points:

Keep hands away from bendingshoe, rollers and conduit whenbender is in use.


Extension cords:

• Use only three-wire, 12-AWGextension cords that have three-prong grounding-type plugs andthree-hole receptacles that acceptthe tool’s plug.

• Do not use extension cords thatare longer than 30 m (100').

• Repair or replace damagedextension cords.


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


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 chainmust be at least 915 mm (36") long to prevent contactwith the bender. All lifting components must be rated for231 kg (510 lb).

1. Pivot the bending head to the horizontal positionwith the 1-1/2" to 2" shoe upward (see Pivoting theBender Head in this section of the manual).

2. Rotate the lifting eyes so they are accessible.

3. Loop the slings through, or attach the hooks to, thelifting eyes.

4. Hoist the bender.

Pivoting the Bender Head

The bender head has two bending positions — verticaland horizontal. To change the bender head position:

1. Pull out the bender head pivot lock knob. It may benecessary to twist the knob clockwise until the pinclears the frame.

2. Pivot the bending head to the desired bendingposition.

3. Push the bender head pivot lock knob back intoposition so that the pin is fully engaged in the hole.

4. Twist the pivot lock knob counterclockwise until youfeel some resistance. Do not tighten it.

Lowering the Jack Screws

The bender is equipped with four jack screws. To parkthe bender at the jobsite, use the 5/16" T-handle Allenwrench, which is shipped in the lockable storage area,to lower two of the jack screws. If desired, lower all fourjack screws to level the bender.


854 Quad Bender

Maintenance

Wear eye protection when operatingor servicing this tool.

Failure to wear eye protection couldresult in serious eye injury fromflying debris.


Disconnect the unit from powerbefore servicing.


Component Maintenance Activity Maintenance Interval

Chain Lubrication and Tension Every 6 months*Adjustment

Roller Supports Cleaning and Lubrication Every 6 months*

Commutator When drive unit

Brushes Replacement performancediminishes noticeably

Schedule

*More often if the bender is used in dusty or corrosive environments

Chain Lubrication and Tension Adjustment

1. Disconnect the bender from the power source.

2. See the 1-1/2" to 2" Side Exploded View. Removethe 1-1/2" to 2" shoe (see Changing Shoes in thissection of the manual).

3. See the Main Exploded View. Remove the screws(23) and front chain guard assembly (4).

4. Spray a motorcycle chain lubricant on the inside ofthe chain between the sprockets while pressingUNLOAD. Lubricate the entire length of the chain.

5. Check the amount of slack halfway between thesprockets. If the chain slack is :

• More than 25 mm (1"), proceed to step 6.

• Less than 25 mm (1"), proceed to step 10.

6. Remove 11 screws (23) and motor guard (5).

7. Loosen the two motor mounting screws (25) on thefront, and the two on the back, and the nut (22).

8. Torque the eccentric locator (21) to 81 Nm (60 ft-lb).Maintain this amount of torque while tightening thenut (22) and two front screws (25).

9. Tighten the two rear screws (25).

10. Assemble in reverse order.

1/2" to 1-1/4" Roller Support


2. Remove support pivot pin (19). Remove rollersupport (7).

3. Spray a motorcycle chain lubricant through the3 mm (1/8") diameter hole in each roller. Rotateeach roller to distribute the lubricant.

4. Spray the pivot pin.

5. Wipe away any excess lubricant.

6. Replace the roller support and pivot pin.


854 Quad Bender

1-1/2" to 2" Roller Support


2. Remove the 1-1/2" to 2" shoe (see Changing Shoesin this section of the manual).

3. See the 1-1/2" to 2" Roller Support Unit ExplodedView. Use a pair of needlenose pliers to disconnectthe springs (104) from the holes in the side of thebender frame beneath the roller support unit.

4. See the Main Exploded View. Remove the squeezeadjustment arm screw (97) and arm (74).

5. Remove the three button head cap screws (96) andadapter sleeve (92).

6. Place one hand under the support arms (71) tosupport the weight of the roller support unit.Remove the eccentric shaft (91).

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

10. Clean off all of the grease and dirt.

11. Inspect each item. Replace any worn, damaged, ormissing items.

12. Lubricate all working surfaces with a high-qualitygrease.

13. Replace all components in reverse order, noting thefollowing:

• On both roller groups: To ease the assembly ofthe split roller subassemblies, begin by slippingthe O-rings onto the side plates. Assemble thesplit roller subassemblies as shown, then slip theO-rings into their correct positions.

• On the 2" roller group only: After replacing anysplit roller components, add or remove shimwashers (99, 119, or 150) as needed.

• On the 1-1/2" roller group: Install the twoBelleville washers (100) so that the inside diam-eters contact each other.

• Use Loctite® 271 on the two hex head screws(93). Torque to 55 to 61 Nm (40 to 45 ft-lb).

14. Position the roller support arms (71) as shown.Assemble the roller groups to the support arms.

15. Reinstall the roller support unit to the bender. Keepone hand under the support arms so they do notdrop completely below the set screw (107).

16. Insert the eccentric shaft (91).

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

17. Install the adapter sleeve (92) and three buttonhead cap screws (96).

18. Install the adjustment arm (74) and adjustment armscrew (97).

19. Attach the springs (104) to the holes in the side ofthe bender frame beneath the roller support unit.

20. Put the bender in the horizontal bending position.Adjust the set screw (107), if necessary, so that thesupport arms (71) are centered between the frontand back plates. Engage and disengage the rollersupport unit to be sure that it moves freely.

Maintenance (cont’d)

Pinch points:Use both hands to hold the two leadand two tail rollers to prevent therollers from pivoting.

Failure to observe this precautioncould result in injury or propertydamage.

7. Lift the roller support subassembly to the left andupward.

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

• Loosen the sleeve set screw (98) and remove the1-1/2" pivot roller shaft (86) with grip (90).Remove the sleeve (87).

• Remove two hex head screws (93). Remove theouter roller plate (75).

• Remove the tail roller (84).

• Remove all components of the split rollerassembly.

9. On the 2" roller group:

• Loosen the sleeve set screw (98) and press outthe 2" pivot shaft (88). Remove the sleeve (89).

• Remove the hex head screw (93). Remove oneretaining ring (95) from the tail roller shaft (83).Remove outer roller plate (76).

• Remove the tail roller (82) and center roller (85).

• Remove all components of the split rollerassembly.


854 Quad Bender

Maintenance (cont’d)Changing Shoes

1. Disconnect the bender from the power source.2. Lock the bender head in the vertical bending

position (see Pivoting the Bender Head in theTransportation and Setup section of this manual).

3. See the 1/2" to 1-1/4" Side Exploded View or the1-1/2" to 2" Side Exploded View. Use heavy-dutyretaining ring pliers to remove the retaining ring (26)that secures the shoe.

4. Remove the shoe from the spindle.

Drive lugs must engage in these holes.

5. Mount the replacement shoe onto the spindle. Alignthe slot in the shoe bore with the screw head on thespindle. Push the shoe onto the spindle until thedrive lugs are fully engaged in the drive lug holes.Replace the retaining ring.

Setting Roller Support Limit Switch

The switch is activated by the main outer roller supportarm, in the retracted position. Retract the switch fromthe maximum switch travel by pivoting the switch in itsmounting holes and rotating it clockwise in its mountingslot.

Set the squeeze adjustment at the maximum clockwiseposition. Move the switch in a counterclockwise direc-tion (with a 0.030" feeler gage between the roller armand the body). When the roller, arm, gage, and switchbody are in contact, tighten the mounting screws.

The switch lockout circuit is normally closed. Attachalligator clips to the common and normally closed switchterminals to check switch trip operation. Do not insertmeter probes into the Molex plug.


854 Quad Bender

Maintenance (cont’d)Setting Angular Position Limit Switch

Set 105° stop switch for maximum 1-1/2" to 2" shoerotation.

Rotate 1-1/2" to 2" shoe in the bend direction until thepointer is at 105°.

Max. Bend Angle

Reduced

Bend Angle

SwitchRetainingScrews

Loosen the socket head cap screws. Move the switch tothe maximum bend angle position, and then move theswitch in the reduced bend angle direction until theswitch is activated and continuity exists at the normallyopen connections. Tighten the two mounting screws toretain the switch.

Note: The lower switch mounting slots are not used.

Pointer Accuracy

Note: Pointers may be adjusted with shoes on thespindle.

1. Loosen the two locking screws (29).

2. Move the pointer (30 or 31).

3. Tighten the screws.

Locking Screws

Commutator Brushes


2. See the Main Exploded View. Remove the 11screws (23) and the motor guard (5). Remove themotor guard.

3. Remove the power cord strain relief (37).

4. Refer to Drive Unit Exploded View. Remove the twoAllen screws and nuts that secure the shroud (6) tothe motor. Remove the shroud.

5. Push in the commutator brush retainer and move ittoward the brush (1) to release it. Unplug the brushand remove it. Replace the brush if it is less than6 mm (1/4") long.

6. Repeat step 5 for the other brush.

7. Assemble in reverse order.


854 Quad Bender

Troubleshooting

Problem Probable Cause Possible Remedy

Bender will not operate. No voltage. Check supply voltage circuitoperation.

Check that switch is ON.

Bender operates in wrong Wrong side of bender selected. Set selector switch properly.direction.

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

Retighten locking screws.

Too much squeeze on 1-1/2" or 2" Back squeeze off per adjustmentEMT or IMC conduit. instructions.

Unusual conduit characteristics. Adjust pointer or bend to a smallerangle to compensate.

Bends are underbent a few Pointer is adjusted wrong. Loosen pointer locking screws anddegrees. rotate counterclockwise to compensate.

Retighten locking screws.

Too little squeeze on 1-1/2" or 2" EMT Increase squeeze per adjustmentor IMC conduit. instructions.

Unusual conduit characteristics. Adjust pointer or bend to a largerangle to compensate.


854 Quad Bender

Troubleshooting (cont’d)

The following flow charts show the suggested trouble-shooting procedures for some bender problems. Theyby no means encompass all possible problems orsolutions.


• Contact with live circuits can resultin severe injury or death.

• Some troubleshooting stepsrequire power to the bender.This type of troubleshooting stepshould only be performed atauthorized Greenlee servicecenters by personnel who arefamiliar with safe troubleshootingprocedures.


YES

YES

NO

YES

YES

YES

Won’t bend

NOIs 115 VAC measured atPGU board input?

Plugged into dead circuit,bad power cord, orswitch is bad or off.

YES Replace PGU.Are metal oxide varistors(MOVs) on PGU boarddamaged or discolored?

NODoes the green LED onthe PGU light? Replace PGU.

NOUnplug pendant or I/O andcheck switch for continuity.If ok, replace I/O.

Does amber or red LEDon I/O light when BENDor UNLOAD is pressed?

NODoes relay on I/Ooperate when BEND orUNLOAD is pressed?

Replace I/O.

Replace PGU.

NO Replace I/O boardassembly.

Does the green LED onthe I/O board light?

YES

YES

NO

YES

NO

Trips circuit breaker

Are the proper support rollersand shoe groove being used forthe type and size of conduitbeing bent?

NO Follow directions ininstruction manual.

Is the current on the 115 VACline exceeding 20 amps?

NO Replace circuitbreaker.

Is the DC current to the motorexceeding 17 amps?

YES Replace motor.

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

NO Replace bridgerectifier(918 5997.2).

Are connectors corroded? YES Clean.

Replace PGU.

NO

NO

Won’t stopYES Use 115 VAC.Is the supply line voltage low?

YES Replace pendantswitch.

Does bender stop when thependant is unplugged?

Replace PGU.

NO

YES

Bender only runs in one direction

NO

YESOn 854 move pendant plug toI/O board. Does bender run bothdirections?

Replace directionswitch assembly.

NO Check and replacependant switch.

Does amber or red LED lightwhen switch is pressed?

YES Replace918 6645.6 relay.

When amber or red LED is on, is12 VDC measured at large relaycoil on PGU (where relay wireunit connects)?

NOReplace I/O.

Move 6-wire connector on PGUfrom “TO I/O” to “TEST.” Alter-nately press BEND and UNLOAD.Does yellow “DIRECTION” LED onPGU turn on and off?

YES

Replace PGU.


854 Quad Bender

1/2" to 1-1/4" Side Exploded View

7

19

204

205

206 213 5

26

23

43 Shoe Unit 1/2" to 1-1/4" consistsof 221, 222, 223, 224 and 225

223

225

224

222

225221

205

206


854 Quad Bender

1-1/2" to 2" Side Exploded View

3

207

215

207

215

213

74 96

91

92

26

224

226

227

228

229

44 Shoe Unit 1-1/2" to 2" consistsof 224, 226, 227, 228 and 229

232

The Roller Support Unitexploded view is onthe following page.

97

226

158

157

163160

155

159

154

164

156

165

167166

161162


854 Quad Bender

1-1/2" to 2" Roller Support Unit Exploded View and Parts List

71 38221 503 8221.7 Support weldment, roller ..................... 1

72 00528 500 0528.6 Support weldment, 1-1/2" ................... 1

73 00601 500 0601.0 Support weldment, 2" .......................... 1

74 38225 503 8225.0 Arm weldment, adjustment ................. 1

75 00543 500 0543.0 Plate, 1-1/2" outer roller ...................... 1

76 00604 500 0604.5 Plate, 2" outer roller ............................ 1

77 38254 503 8254.3 Split rollers, 1-1/2" .............................. 2

78 38264 503 8264.0 Ball, 1-1/2" ........................................... 2

79 38255 503 8255.1 Split rollers, 2" ..................................... 2

80 38263 503 8263.2 Ball, 2" ................................................. 2

81 38262 503 8262.4 Spacer, 2" roller .................................. 1

82 00599 500 0599.5 Roller unit, 2" ...................................... 1

83 00493 500 0493.0 Shaft, 2" rear roller .............................. 1

84 38252 503 8252.7 Roller, 1-1/2" IMC ............................... 1

85 38253 503 8253.5 Roller, 2" Tail ...................................... 1

86 38260 503 8260.8 Shaft, 1-1/2" pivot roller ...................... 1

87 32027 503 2027.0 Sleeve, 1-1/2" ...................................... 1

88 31728 503 1728.8 Shaft, 2" pivot ...................................... 1

89 38151 503 8151.2 Sleeve, 2" ............................................ 1

90 23258 502 3258.4 Grip ...................................................... 1

91 38256 503 8256.0 Shaft, eccentric ................................... 1

92 38251 503 8251.9 Sleeve adapter .................................... 1

93 50540 905 0540.9 Screw, 7/16-14 x 1.00 hex hd ............. 2

94 00860 500 0860.9 Shaft, 1-1/2" support ........................... 1

95 54819 905 4819.1 Retaining ring #5100-87 ..................... 2

96 54242 905 4242.8 Screw, cap 1/4-20 x .37 btn hd ........... 3

97 50224 905 0224.8 Screw, 5/16-18 x 1.00 skt hd .............. 1

98 50881 905 0881.5 Screw, 1/4-28 x .25 set ....................... 2

99 53918 905 3918.4 Washer, 1.00 x 1.37 x .03 shim .......... 1

100 54248 905 4248.7 Washer, Belleville 1.362 x .803 .......... 2

101 39440 503 9440.1 Washer, .62 x 2.00 x .06 Flat ............. 1

104 54243 905 4243.6 Spring, extension .75 x 3.50 ............... 2

105 54252 905 4252.5 Clamp, loop-type ................................. 1

115 38592 503 8592.5 Guide, spring ....................................... 1

116 51130 905 1130.1 O-Ring, 1.50 x 1.62 x .062 .................. 2

117 51537 905 1537.4 O-Ring, 1.75 x 1.87 x .062 .................. 2

118 38657 503 8657.3 Shaft, 2 middle roller ........................... 1

119 52644 905 2644.9 Washer, 1/32 shim .............................. 1

150 52645 905 2645.7 Washer, 1/16 shim .............................. 1

151 53216 905 3216.3 Retaining ring #5100-62 ..................... 1

152 07323 500 7323.0 Roller, 1.00 .......................................... 1

153 07322 500 7322.2 Sleeve, .940 ........................................ 1

178 55305 905 5305.5 Screw, 7/16-14 x 1.75 ......................... 1

500 0574.0 Roller Support Unit consists of:

UPC No.Key 78-3310- Part No. Description Qty.


95118

8973

98117

71104

8472

115

86116

7877

10077

7898

116

87 94 7593*

151 10190

99, 119or 150

*Torque to 94 Nm (70 ft-lb)

93*88

76

117

95104

8385

10582

8079

8179

80

152153

178*


854 Quad Bender

Drive Unit Exploded View and Parts List

1. Torque gearbox bolts to 11/9 Nm (100/80 in-lb) insequence shown.

2. Assemble all Belleville washers so that I.D.’s buttand O.D.’s contact bearings.

3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb).

4. Insert commutator brushes before connectingpush-on terminals.

UPC No.Key 78-3310- Part No. Description

1 86705 918 6705.3 Commutator brushes

2 86706 918 6706.1 Commutator brush retension springs

3 86707 918 6707.0 Tail housing

4 86708 918 6708.8 Brush assembly plate

5 86709 918 6709.6 Cord

6 39092 503 9092.9 Shroud

7 86710 918 6710.0 Magnet housing

8 86711 918 6711.8 Armature

8A 86071 918 6071.7 Bearing

9 54348 905 4348.3 Belleville washers

10 39073 503 9073.2 Rear gear housing

11 39074 503 9074.0 Gasket

12 39075 503 9075.9 Front gear housing

13 39076 503 9076.7 Output gear shaft

14 39077 503 9077.5 Short spacer

15 39078 503 9078.3 Long spacer

16 39079 503 9079.1 2nd Reduction pinion shaft w/ BRGs

17 53323 905 3323.2 Wave washer

18 39080 503 9080.5 3rd Reduction pinion shaft w/ BRGs

19 54248 905 4248.7 Belleville washer

20 39081 503 9081.3 4th Reduction pinion shaft

21 39082 503 9082.1 Small spacer

22 54043 905 4043.3 1/2-20 x 2-1/2 Screw

23 02298 500 2298.9 1/4-28 x 9-1/4" Stud

24 51705 905 1705.9 1/4-28 hex nut

25 50749 905 0749.5 1/4" Internal tooth lock washer

26 07208 500 7208.0 Oil seal

27 07209 500 7209.9 Oil seal

Bolt Tightening Sequence for Gearbox Cover

6

4 3

1

2 5

22

26

27

23

10

253

4

24 6

5

2

1

20

21

16

1513

14

17

1918

12

7

1

2

9

23

8

11

8A

22


854 Quad Bender

Main Exploded View

358

5

7

19

205

205

206

206

213

204

215

13

17

1211

161027

23

2932

8

201

6

202474645

207

15

2

15

15

2533

21

209, 211, 212

51

50

225223

222

225

221

224

22

20A

14, 28

220

60

170

59

2052

208

43

23

Power Cord 37170

30 233

233

26

165167

166

169 168167

166

173

UN

LOA

D

BE

ND

18

236

142


854 Quad Bender

If the chain breaks, replace it with a newchain — not another master link — dueto the high stress on the chain. Theaddition of a second master link will onlyweaken the chain further. If the masterlink breaks, replace it with a new masterlink (905 4251.7).

95118

8973

98117

71104

8472

115

86116

7877

10077

7898

116

87 94 7593*151 101 90

99, 119or 150

*Torque to 94 Nm (70 ft-lb)

93*88

76

117

95

10483

85105

82

8079

8179

80

Note: These items are available asPart No. 500 0574.0Roller Support Unit.

152153

178*

106107

9692

9121

7497

6

158

157163160

159

164

156

155

154

161162

4, 4A26

176

29

31

207

203

15

224

228226

227

226

229

4C4B

220

44

23

171172 231

235234 9

18


854 Quad Bender



Main Parts List

2 01622 500 1622.9 Frame weldment ................................. 1

3 38217 503 8217.9 Guard weldment, top chain ................. 1

4 38983 503 8983.1 Guard assembly, front chain ............... 1

4A 38236 503 8236.5 Guard, front ......................................... 1

4B 38244 503 8244.6 Retainer ............................................... 1

4C 50160 905 0160.8 Rivet, 3/16" pop .................................. 2

5 38232 503 8232.2 Guard weldment, motor ...................... 1

6 01607 500 1607.5 Guard, bottom ..................................... 1

7 38199 503 8199.7 Support weldment,1/2" to 1-1/4" RLR ............................... 1

8 38250 503 8250.0 Drive unit ............................................. 1

9 01702 500 1702.0 Spindle weldment, main ..................... 1

10 38193 503 8193.8 Plate weldment, drive ......................... 1

11 54253 905 4253.3 Sprocket, #60 14T .............................. 1

12 38267 503 8267.5 Key, drive sprocket ............................. 1

13 54255 905 4255.0 Bearing, sleeve #48DU40 ................... 2

14 54250 905 4250.9 Chain, #60 92P ................................... 1

15 54462 905 4462.5 Ring, retaining Truarc #5100-200 ....... 4

16 38265 503 8265.9 Washer, main spindle ......................... 2

17 38268 503 8268.3 Key, shoe drive ................................... 1

18 38457 503 8457.0 Plate, hoist .......................................... 2

19 55204 905 5204.0 Pin, 1/2" to 1-1/4" support pivot .......... 1

20 38257 503 8257.8 Spacer, motor mount .......................... 1

20A 39488 503 9488.6 Spacer, thin motor mount ................... 1

21 38228 503 8228.4 Locator weldment, eccentric ............... 1

22 54265 905 4256.8 Nut, 1/2-13 lock ................................... 1

23 51655 905 1655.9 Screw, #10-16 x .50 hex head .......... 31

25 53903 905 3903.6 Screw, cap 1/2-13 x 1.00 .................... 4

26 52501 905 2501.9 Ring, retaining Truarc #5100-287 ....... 2

27 54345 905 4345.9 Screw, set 1/2-20 x .75 socket ........... 1

28 54251 905 4251.7 Link, connecting #60 chain ................. 1

29 52871 905 2871.9 Screw, 1/4-20 x .75 socket ................. 4

30 03095 500 3095.7 Pointer, 1/2" to 1-1/4" .......................... 1

31 03099 500 3099.0 Pointer, 1-1/2" to 2" ............................. 1

32 03104 500 3104.0 Spacer, pointer .................................... 2

33 52597 905 2597.3 Washer, flat .56 x 1.37 x .109 ............. 4

37 54124 905 4124.3 Strain relief .......................................... 1

43 38780 503 8780.4 Shoe unit, 1/2" to 1-1/4" ...................... 1

44 38148 503 8148.2 Shoe unit, 1-1/2" to 2" ......................... 1

45 52203 905 2203.6 Screw, machine #6-32 x .25 ............... 2

46 29708 502 9708.2 Guard, breaker switch ......................... 1

47 86385 918 6385.6 Breaker, circuit 20 amp ....................... 1

50 54927 905 4927.9 Screw, cap #8-32 x 1.37 socket ......... 4

51 86841 918 6841.6 Brake, motor ....................................... 1

52 38807 503 8807.0 Key, brake ........................................... 1

54 54151 905 4151.0 Knob, plastic w/ set screw .................. 1

58 03129 500 3129.5 Decal, angle ........................................ 2

59 51751 905 1751.2 Screw, drive ........................................ 460 03101 500 3101.5 Nameplate ........................................... 1

61 38892 503 8892.4 Decal, warning (not shown) ................ 1

62 38893 503 8893.2 Decal, lifting eye (not shown) ............. 1

65 03105 500 3105.8 Decal, select switch size(not shown) ......................................... 1

67 38898 503 8898.3 Decal, bender pivot lock(not shown) ......................................... 1

68 38899 503 8899.1 Decal, roller adjustment(not shown) ......................................... 1

69 02263 500 2263.6 Decal, roller engagement(not shown) ......................................... 1

70 03100 500 3100.7 Decal, operation (not shown) ............. 3

71 38221 503 8221.7 Support weldment, roller ..................... 1

72 00528 500 0528.6 Support weldment, 1-1/2" ................... 1

73 00601 500 0601.0 Support weldment, 2" .......................... 1

74 38225 503 8225.0 Arm weldment, adjustment ................. 1

75 00543 500 0543.0 Plate, 1-1/2" outer roller ...................... 1

76 00604 500 0604.5 Plate, 2" outer roller ............................ 1

77 38254 503 8254.3 Rol, 1-1/2" ........................................... 2

78 38264 503 8264.0 Ball, 1-1/2" ........................................... 2

79 38255 503 8255.1 Rol, 2" .................................................. 2

80 38263 503 8263.2 Ball, 2" ................................................. 2

81 38262 503 8262.4 Spacer, 2" roller .................................. 1

82 00599 500 0599.5 Roller unit, 2" ...................................... 1

83 00493 500 0493.0 Shaft, 2" rear roller .............................. 1

84 38252 503 8252.7 Roller, 1-1/2" IMC ............................... 1

85 38253 503 8253.5 Roller, 2" tail ........................................ 2

86 38260 503 8260.8 Shaft, 1-1/2" pivot roller ...................... 1

87 32027 503 2027.0 Sleeve, 1-1/2" ...................................... 1

88 31728 503 1728.8 Shaft, 2" pivot ...................................... 1

89 38151 503 8151.2 Sleeve, 2" ............................................ 1

90 23258 502 3258.4 Grip ...................................................... 1

91 38256 503 8256.0 Shaft, eccentric ................................... 1

92 38251 503 8251.9 Sleeve, adapter ................................... 1

93 50540 905 0540.9 Screw, 7/16-14 x 1.00 hex head ......... 2

94 00860 500 0860.9 Shaft, 1-1/2" support ........................... 1

95 54819 905 4819.1 Retaining ring #5100-100 ................... 2

96 54242 905 4242.8 Screw, cap 1/4-20 x .37button head ......................................... 3

97 50224 905 0224.8 Screw, 5/16-18 x 1.00 socket head .... 1

98 50881 905 0881.5 Screw, 1/4-28 x .25 set ....................... 2

99 53018 905 3918.4 Washer, 1.00 x 1.37 x .03 shim .......... 1

100 54248 905 4248.7 Washer, Belleville 1.362 x .803 .......... 2

101 39440 503 9440.1 Washer, .62 x 2.00 x .06 flat ............... 1

104 54243 905 4243.6 Spring, extension .75 x 3.50 ............... 2

105 54252 905 4252.5 Clamp, loop-type ................................. 1

106 52108 905 2108.0 Nut, hex 1/4-20 ................................... 1

107 54239 905 4239.8 Screw, 1/4-20 x 3/4 ovl pt set ............. 1

115 38592 503 8592.5 Guide, spring ....................................... 1

116 51130 905 1130.1 O-ring, 1.50 x 1.62 x .062 ................... 2

117 51537 905 1537.4 O-ring, 1.75 x 1.87 x .062 ................... 2


854 Quad Bender

Main Parts List (cont’d)



118 38657 503 8657.3 Shaft, 2 middle roller ........................... 1

119 52644 905 2644.9 Washer, 1/32 shim .............................. 1

142 07887 500 7887.9 Pendant control assembly .................. 1

143 07912 500 7912.3 Power cord assembly ......................... 1

150 52645 905 2645.7 Washer, 1/16 shim .............................. 1

151 53216 905 3216.3 Retaining ring ...................................... 1

152 07323 500 7323.0 Roller, 1.00 .......................................... 1

153 07322 500 7322.2 Sleeve, .940 ........................................ 1

154 07314 500 7314.1 Nest, spring ......................................... 1

155 07317 500 7317.6 Rod, spring .......................................... 1

156 07318 500 7318.4 Retainer, spring ................................... 1

157 07319 500 7319.2 Pivot cam ............................................ 1

158 07321 500 7321.4 Retaining cam ..................................... 1

159 55285 905 5285.7 Spring .................................................. 1

160 55284 905 5284.9 Spherical rod end,1/4-28 thd male ................................... 1

161 50985 905 0985.4 Ring, retaining, 5100-100 ................... 1

162 52749 905 2749.6 Nut, self-locking, 3/8-24 ...................... 1

163 55222 905 5222.1 Screw, 5/16-18 x .75 skt hd cap ......... 1

164 55269 905 5269.5 Bolt, 1/4-28 x .50 Gr #8, hex head ..... 1

165 55302 905 5302.0 Screw, #6-32 x 1.25 skt hd mach ...... 2

166 38248 503 8248.9 Back plate, switch ............................... 2

167 85822 918 5822.4 Switch, limit #BZ-2RW822-A2 ............ 2

168 38246 503 8246.2 Bracket, limit switch ............................ 1

169 54240 905 4240.9 Screw, #6-32 x 1.00 skt hd mach ....... 2

170 86263 918 6263.9 Nut, 1/2" conduit lock .......................... 1

171 86890 918 6890.4 Ring, locking ....................................... 1

172 86983 918 6983.8 Boot, toggle, 1/2, black ....................... 1

173 54335 905 4335.1 Screw, flange 1/4 x .37 thd ................. 2

174 38974 503 8974.2 Decal, circuit breaker (not shown) ...... 1176 54911 905 4911.2 Screw, 1/4-28 x 3/8"

socket head cap .................................. 2

177 01453 500 1453.6 Decal, shoe orientation(not shown) ......................................... 2

178 55305 905 5305.5 Screw, 7/16-14 x 1.75 ......................... 1

201 38141 503 8141.5 Base weldment, Trunion ..................... 1

202 03135 500 3135.0 Tower weldment, L.H. Trunion ........... 1

203 03136 500 3136.8 Tower weldment, R.H. Trunion ........... 1

204 53390 905 3390.9 Wheel .................................................. 2

205 38613 503 8613.1 Axle, short ........................................... 2

206 51528 905 1528.5 Ring, retaining #5160-75 .................... 4

207 54237 905 4237.1 Screw, flange 3/8-16 x 1.00 hx ......... 16

208 52646 905 2646.5 Nut, 3/8-16 Esna hex .......................... 4

209 38167 503 8167.9 Pin, Trunion lock ................................. 1

211 54244 905 4244.4 Spring, Trunion lock ............................ 1

212 38168 503 8168.7 Knob .................................................... 1

213 38464 503 8464.3 Pad weldment, jack bolt ...................... 4

215 54276 905 4276.2 Caster, swivel ...................................... 2

220 38156 503 8156.3 Block, reinforcement ........................... 2

221 31710 503 1710.5 1/2" to 1-1/4" IMC, Rigid hook ............ 1

222 33494 503 3494.8 1/2" to 1-1/4" Shoe .............................. 1

223 31712 503 1712.1 1/2" to 1-1/4" EMT hook ...................... 1

224 52479 905 2479.9 Drive bolt, 1/2-13 x .62socket head cap screw ....................... 6

225 51088 905 1088.7 1/2" to 1-1/4" Hook bolts,3/8-16 x 1-1/4socket head cap screw ....................... 8

226 53396 905 3396.8 1-1/2, 2" Hook shoulder bolts,3/4 x 1-1/2 ........................................... 6

227 38147 503 8147.4 1-1/2, 2" shoe ...................................... 1

228 31716 503 1716.4 1-1/2, 2" EMT hook ............................. 1

229 38779 503 8779.0 1-1/2, 2" IMC and rigid hook ............... 1

231 07942 500 7904.2 Selector switch unit ............................. 1

232 54880 905 4880.9 Wrench, 5/16" hex T-handle ............... 1

234 50645 905 0645.6 Nut, 5/16-18 reg jam ........................... 2

235 50224 905 0224.8 Screw, 5/16-18 x 1, socket head ........ 2

236 54355 905 4355.6 Washer, flat .158 x .380 x .050 ........... 4

07248 500 7248.6 Decal, extension cord (not shown) ..... 1

Optional

38962 503 8962.9 Vinyl cover (not shown)

01700 500 1700.4 1/2" to 2" PVC shoe group

Service Only

05586 500 5586.0 Frame unit (includes bearings) ........... 1233


854 Quad Bender

Wiring Diagram

120D

120C

120B

120A

121

51TO B

RAKE

123

GREEN

WHITE

BLACKTO

DRI

VE U

NIT

122

143

GREE

N

WHI

TE

BLAC

KBL

ACK

WHI

TE

BLAC

K

RED

TO I/O

TO R

ELAY

BLAC

K RE

D

BLACKRED

FROM RECTIFIER

YELLOW

BLAC

K

RED

WHI

TE

WHI

TE

+HV

-HV AC

AC

YELLOW

YELL

OWYELL

OW

CN2

CN1

JP1

GREE

N

BLAC

K

47

23

COM

NONC

NCNO

COM

BLAC

K

BLAC

K

WHI

TE

WHI

TE

167

(LOC

ATED

UND

ER T

OP C

OVER

)16

7(L

OCAT

ED U

NDER

ROL

LER

SUPP

ORT)

TO P

ENDA

NT17

0

172

231

171

120

XX


854 Quad Bender

Wiring Diagram Parts List

120 500 6018.0 854 I/O Control assembly ....................................... 1

120A 500 6037.6 Wire unit, power — DC........................................... 1

120B 500 6036.8 Wire unit, power — AC ........................................... 1

120C 503 8648.4 Wire unit, I/O — PGU ............................................. 1

120D 500 6040.6 Wire unit, ground .................................................... 1

121 500 5467.8 PGU2 assembly ...................................................... 1

122 503 8941.6 Wire unit, PGU to breaker ...................................... 1

123 918 6839.4 Wire unit, I/O to PGU.............................................. 1

127 500 3052.3 Switch, PCB direction ............................................. 1

128 905 4279.7 Tie, cable (not shown) ............................................ 3

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

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

167 918 5822.4 Switch, limit #BZ-2RW822-A2 ................................ 2

*231 500 7904.2 Switch with wire harness (direction) ...................... 1

* Switch only (without wire harness) can be purchased asrepair part 918 6981.1

Key Part No. Description Qty.


854 Quad Bender

I/O Electrical Schematic (500 6018.0)

Note

: Al

l res

isto

rs 5

% 1

/4W

unl

ess

note

d.

+5V

+12V

+12V

+5V

+12V

+5V

+12V

+12V

+5V

+5V

RUN/

BRAK

E

_RUN

/BRA

KE_

_DIR

ECTI

ON_

_PW

M_

DIR

BDI

R A

PWM

DIRE

CTIO

N

MEC

H BR

AKE

UNUS

ED2

UNUS

ED1

65

43

21 TO

PGU

Mol

ex 3

9-28

-106

3

JP5

54321

DC P

OWER

INM

olex

26-

60-4

050

JP1

18RA

1/AN

1

17RA

0/AN

0

16OS

C1/C

LKIN

15OS

C2/C

LKOU

T

13RB

7

12RB

6

11RB

5

10RB

4

9RB

3

8RB

2

7RB

1

6RB

0/IN

T

4M

CLR

3RA

4/TO

CKI

2RA

3/AN

3

1RA

2/AN

2/VR

EF

PIC1

6C62

0

U1

10K

R23

10K

R22

UF10

01DI

D1

UF-1

001-

DID5

UF-1

001-

DID4

1N41

48D3

PN22

22A

Q4PN

2222

AQ3

PN22

22A

Q2

POW

ERGR

EEN

LED

D2

DIR

BAM

BER

LED

D7

DIR

ARE

D LE

DD6

10K

R18

.1uF

/50V

C1

330

R6

21

RELA

Y CO

ILM

olex

39-

28-1

023

JP3

21

MEC

HANI

CAL

BRAK

EM

olex

39-

28-1

023

JP2

470

R5

TIP1

22Q1

150

R10

43

21

PEND

ANT

Mol

ex 3

9-28

-104

3

JP4

.1uF

/50V

C4

330

R21

.1uF

/50V

C3

330

R20

10K

R17

10K

R16

10K

R15

31

2

4.0

MHz

X1

10K

R7

10K

R410

KR3

10K

R210

KR1

470

R14

1KR19

470

R13

150

R12

470

R11

4.7u

F/50

VC2

1KR9

10K

R8


854 Quad Bender

I/O Electrical Schematic (500 6018.0) Parts List

Reference Supplier Part Number Description Qty.C1,C3,C4 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 3

AVX SA115C104KAAKEMET 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 1Liteon LTL-4231

D3 Generic 1N4148 Diode 1

D6 Panasonic LN28RP LED, T1, Red 1Liteon LTL-4221

D7 Panasonic LN48YP LED, T1, Amber 1Liteon LTL-4251

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 1Generic #4-40 Lock Washer Stainless Steel, Split Ring or Internal Tooth 1Generic #4-40 Hex Nut Stainless Steel 1Generic #4-40 Phillips Screw Stainless Steel, Machine, Pan Head, #4-40 x 0.25" 1

Q2,Q3,Q4 Generic PN2222A Transistor, NPN 3

R1,R2,R3,R4,R7,R8,R15, Generic Resistor, 10K, 1/4 watt, 5% 12R16,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 1Panasonic EFO-GC4004A4


854 Quad Bender

PCB Layout (500 6018.0)

Q1

JP1

R22

RELAYBRAKE

TO PGU

POWER

JP41

2

34

JP5 12

3

45

6

R15

R1

D4

R21

C4

R18

D7

DIR A

JP3

1 2

Q3

R13

R8

R9

C2+

D3

R5

DIR B

JP2

1

2

R6

C1

D2

X1

D1

R20

C3

D6

R17

D5

R11

R12

R19

R14

R10

Q2

Q4

R23

U1

SELE

CTOR

R3R4R7

GREENLEE TEXTRON ©2000

R2

R16


854 Quad Bender

Power Generation Unit Schematic Diagram (500 5467.8)

Do n

ot tr

im in

sula

tor.

in h

eat s

ink.

Q1 s

houl

d m

ount

to u

pper

hol

e

in h

eat s

ink.

D8 s

houl

d m

ount

to lo

wer

hol

e

Tigh

ten

Q1 a

nd D

8 to

5 in

-lb

#4-4

0 Ph

illip

s Sc

rew

#4-4

0 Nu

t#4

-40

Lock

Was

her:

#4-4

0 Fl

at W

ashe

r (x2

)

KA-1

18-0

94

Pow

er D

evic

es, I

ncIn

sula

tor:

TH

M70

23B-

MT

Th

erm

allo

y In

c.He

atsi

nk:

Mou

ntin

g Ha

rdw

are

for Q

1 an

d D8

7

54

81

62

MIC

4422

BNU2

100K

R10

-+

123

167

LM33

9U1

A

10K/

1%R1

6

20K/

1%R7

4.75

K/1%

R6 1.5K

/1%

R26

+15

V 20K/

1%R2

4

10K/

1%R2

5

-+

123

131011

LM33

9U1

D

+170

V

1N52

45B

D3

21

TO R

ELAY

(Con

tact

s 5

and

8)

BLAC

KJ1

1

21

TO R

ELAY

(Con

tact

s 6

and

7)

RED

J10

DSEI

30-0

6AD8

IXFK

73N3

0Q1

C10

+15

V

.1uF

/50V

.1uF

/50V

C9

VCC

GREE

N LE

D

D4DIRE

CTIO

NYE

LLOW

LED

D1

PWM

RED

LED

D2

2KR82KR1

65

43

21 TEST

CON

NECT

ORM

olex

39-

28-1

063

J1

EVQ-

PAC0

9K

S1

-+

123

245

LM33

9U1

B

100K

R13

1N41

48D6

1MR12

1N41

48D7

1MR14

.01u

F/50

VC3

150K

R41MR2

1MR3

12K/

1%R5

+15

V

27.4

K/1%

R27

1.5K

/1%

R28

.1uF

/50V

C12

10K/

1%R2

3-+ 123

1489

LM33

9U1

C10

0/1%

R22

.040

/5W

/1%

R15

2 35678

2 1

TO R

ELAY

COI

L (C

onta

cts

1 an

d 2)

Mol

ex 3

9-28

-102

3

J4

UF10

01DI

D9

HCPL

4502

U3

65

43

21

TO I/

OM

olex

39-

28-1

063

J2

PN22

22A

Q2

1KR19

1KR21

+15

V

.1uF

/50V

C13

.1uF

/50V

C11u

F/63

VC2 1N

4148

D522R9

22R11

RECT

IFIE

RTO

BRI

DGE

+170

V

+15

V1N

4007

D13

1N40

07

D14

21

ACYE

LLOW

J8

4.7K

/10W

R17

21

DC-

BLAC

K

J9

21

DC+

RED

J6

21

ACYE

LLOW

J5

POW

ERGR

EEN

LED

D11

1N52

45B

D10

20K/

2W/1

%R1

8

680u

F/25

VC7

1000

uF/2

50V

C6

.010

uF/5

00VA

CC4

.010

uF/5

00VA

CC1

1GR

OUND

NEUT

RAL

LINE

.004

7uF/

500V

ACC5 .0

047u

F/50

0VAC

C847

0uH

L11.

5MR2

03 2 1

AC P

OWER

INBe

au 7

2503

-C

J7

Note

s:• B

end

lead

s on

R17

to m

ount

at l

east

0.2

5" o

ff-bo

ard.

• All

resi

stor

s 5%

1/4

W u

nles

s no

ted.

R29

68.1

K


854 Quad Bender

Power Generation Unit Parts List (500 5467.8)

C1,C9,C10,C12,C13 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 5AVX SA115C104KAAKEMET C420C104K5R5CA

C2 WIMA MKS21.06310 Capacitor, Film, 1 uF, 63 volts 1

C3 Philips A103M15Z5UFVVWA Capacitor, .01 uF, 50 volts 1AVX SA105E103ZAA

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 1Cornell Dubilier 380LX102M250K052

C7 Panasonic EEU-FC1E681 Capacitor, 680 uF, 25 volts 1

D1 Panasonic LN48YP LED, T1, Amber 1Liteon LTL-4251

D2 Panasonic LN28RP LED, T1, Red 1Liteon LTL-4221

D3,D10 Motorola 1N5245B Zener Diode, 15 volts, 500 milliwatts 2

D4,D11 Panasonic LN38GP LED, T1, Green 2Liteon LTL-4231

D5,D6,D7 Generic 1N4148 Diode 3

D8 IXYS DSEI 30-06A Diode, Fast Recovery, 30A, 400-600V, TO-247 (see Note 1) 1Adv Pwr Tech APT30D40BAdv Pwr Tech APT30D60B

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 1Magnum A202203

L1 Renco RL-1328-22-470 Choke, Common Mode 1

Q1 IXYS IXFK73N30 MOSFET, N channel, 73-76A, 300V, TO-264 (see Note 2) 1Adv Pwr Tech APT30M40LVFR

Q2 Generic PN2222A Transistor, NPN 1


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



R9,R11 Generic Resistor, 22 Ω, 1/4 watt, 5% 2


R15 Dale LVR-5 .04W Resistor, .040 Ω, 5 watt, 1% 1KRL NP-5A .04WRiedon MT-5 .04W

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) 1KRL C-10A 4.7KRiedon UT-10 4.7K

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

Reference Supplier Part Number Description Qty.


854 Quad Bender

Layout Diagram — Power Generation Unit (500 5467.8)

R18

L1

J7

Q1

+

C6D8

C13

C12

C10

C3

C1

C9

C2

U1

J6

YellowYellow

Red Black

TEST

DIR

PWM

VCC

GREENLEE TEXTRON

POW

ER

R17

65

4

32

1

D2

R8R1

D1

J8J5

J9

D4

R15

D11

D13

Red

Blac

kTO R

ELAY

FROM RECTIFIER

©2000

TO I/O GroundNeutralLine

R28

R12

R4

R22

R2

R27

R3

6 5 4

3 2 1

J2

C4

21

J4

R7

D3

R16

R6R2

3R1

0Q2

U3

R13

R14

D6D7

U2

R26

D5

R9 R11

R5

R24

R25

R19

R21

C5 C8

R20

C11

+

C7

S1

D9

D10

J10

J11

D14

Power Generation Unit Parts List (500 5467.8) (cont’d)

Reference Supplier Part Number Description Qty.

Riedon UT-2B 20K


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



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 1QT-Opto HCPL4502Siemens 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 0.25" off-board.

USA 800-435-0786 Fax: 800-451-2632 815-397-7070 Fax: 815-397-1865Canada 800-435-0786 Fax: 800-524-2853International +1-815-397-7070 Fax: +1-815-397-9247

4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.

www.greenlee.com Printed in USA

sb 283 rev 1 p01-15 - amazon s3€¦ · the o-rings onto the side plates. assemble the split roller...

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