Greenlee

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.
99922223 © 2007 Greenlee Textron Inc. IM 1301 REV 13 10/07

854 Quad Bender
Table of Contents Safety

Description..................................................................... 2 Safety is essential in the use and maintenance of
Safety............................................................................. 2 Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
Purpose.......................................................................... 2 avoiding hazards and unsafe practices related to the
Important Safety Information......................................3–4 use of this tool. Observe all of the safety information
provided.
Grounding Instructions................................................... 5
Identification................................................................... 6
Specifications................................................................. 6 Purpose of this Manual
Transportation and Setup............................................... 7 This manual is intended to familiarize personnel with
Operation.....................................................................8–9 the safe operation and maintenance procedures for the
Illustrated Bending Glossary........................................ 10 following tool:
Bending Instructions...............................................11–12 854 (03106) Serial Number ABT0000
Special Bending Information...................................13–20 Keep this manual available to all personnel.
Maintenance............................................................21–23 Replacement manuals are available upon request at
no charge at www.greenlee.com.
Troubleshooting.......................................................24–25
Exploded Views, Parts Lists,
Schematics and Wiring Diagrams...........................26–49
Description
The Greenlee 854 Quad Bender is an electric-powered
conduit and pipe bender, intended to make up to 90°
bends in 1/2" to 2" 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 01700, 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 15 of the Federal Communications Commission
rules. These limits are designed to provide reasonable
protection against harmful interference when the equip-
ment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio fre-
quency 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 All specifications are nominal and may change as design
which case the user will be required to correct the interfer- improvements occur. Greenlee Textron Inc. shall not be liable for
ence at his own expense. damages resulting from misapplication or misuse of its products.
Do not make any modifications to this device. Unauthorized Loctite is a registered trademark of Loctite Corporation.
changes or modifications will void the user’s authority to
operate this device under United States federal law.
KEEP THIS MANUAL

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
854 Quad Bender
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT Electric shock hazard:
• Connect the power cord to a
SYMBOL 120 volt, 20 amp receptacle on a
ground fault protected circuit only.
See Grounding Instructions.
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or • Do not modify the power cord or
property damage. The signal word, defined below, plug.
indicates the severity of the hazard. The message • Inspect the power cord before
after the signal word provides information for pre- use. Repair or replace the cord if
venting or avoiding the hazard. damaged.
• Disconnect the unit from power
before servicing.
Failure to observe these warnings
Immediate hazards which, if not avoided, WILL result
could result in severe injury or death.
in severe injury or death.
Hazards which, if not avoided, COULD result in

severe injury or death. • Do not expose to rain.
• Do not use in wet or damp
locations.
Hazards or unsafe practices which, if not avoided, • Do not immerse the pendant
MAY result in injury or property damage. switch in water or any other liquid.
Read and understand all of the

instructions and safety information
in this manual before operating or Wear eye protection when operating
servicing this tool. or servicing this tool.
Failure to observe this warning will Failure to wear eye protection could
result in severe injury or death. result in serious eye injury from flying
debris.
Do not use this tool in a hazard-

ous environment. Hazards include Do not remove guards.
flammable liquids, gases, or other
Failure to observe this warning could
materials. Using this tool in a hazard-
result in severe injury or death.
ous environment can result in a fire
or explosion.
Failure to observe this warning will
854 Quad Bender
IMPORTANT SAFETY INFORMATION
Extension cords: • Inspect the bender before each use. Replace worn,
• Use only three-wire, 12-gauge damaged, or missing parts with Greenlee replace-
extension cords that have three- ment parts. A damaged or improperly assembled
prong grounding-type plugs and component could break and strike nearby
three-hole receptacles that accept personnel.
the tool’s plug. • Do not overbend the conduit or pipe. Overbending
• Do not use extension cords that could cause a hook to collide with the conduit or
are longer than 30 m (100'). pipe, resulting in damage to the bender.
• Repair or replace damaged • Conduit moves rapidly as it is bent. Before starting
extension cords. a bend, remove any obstructions from the path of
the conduit.
could result in severe injury or death. • 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
Pinch points: injury or property damage.
Keep hands away from bending
shoe, rollers and conduit when
bender is in use. 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.
854 Quad Bender
Grounding Instructions
This tool must be grounded. In the event of a malfunc-
tion or breakdown, an electrical ground provides a path
of least resistance for the electric current. This path of
Electric shock hazard: least resistance is intended to reduce the risk of electric
shock.
• Do not modify the plug provided
with the tool. This tool’s electric cord has a grounding conductor and
a grounding plug as shown. Do not modify the plug.
• Connect this tool to a grounded
Connect the plug to a corresponding GFCI protected
receptacle on a 20 amp GFCI-
receptacle that is properly installed and grounded
protected circuit.
in accordance with all national and local codes and
Failure to observe these warnings ordinances.
Do not use an adapter.
20 Amp/120 Volt
Plug and Receptacle
Plug Receptacle
854 Quad Bender
Identification
2
2
13
3
12
11
10 15
4
5 9
6
7
14
8 8
854 Conduit Bender
1. Bender Power Head 9. Support Roller Squeeze Adjustment

2. 1/2" to 1-1/4" Bending Shoe 10. Support Roller Engagement Handle
3. On/Off Switch and Circuit Breaker 11. 1-1/2" to 2" Roller Support System
4. Bender Head Pivot Lock Knob 12. 1-1/2" to 2" Bending Shoe
5. Lifting Eyes 13. Shoe Retaining Lock Ring
6. Lockable Storage Area 14. Open Storage Area
7. Support Frame 15. Transport Handle
8. Leveling Jack Screws
Specifications
Height......................................................................................................1200 mm (47")
Width......................................................................................................724 mm (28.5")
Depth......................................................................................................902 mm (35.5")
Mass/Weight (bender without shoes or roller supports)..........................231 kg (510 lb)
Power Supply................................................ 120 VAC, 20 amp GFCI-protected circuit
Operating Conditions
Temperature............................................................... 0 °C to 49 °C (32 °F to 120 °F)
Relative Humidity.........................................................................................0 to 98%
Capacity......................................................... 1/2" to 2" conduit and schedule 40 pipe
854 Quad Bender
Transportation and Setup

Hoisting the Bender Pivoting the Bender Head
To hoist the bender, use either slings (nylon or polyester)
or chains with hooks. Each side of the sling or chain
must be at least 915 mm (36") long to prevent contact
with the bender. All lifting components must be rated for
231 kg (510 lb).
1. Pivot the bending head to the horizontal position
with the 1-1/2" to 2" shoe upward (see Pivoting the
Bender Head in this section of the manual).
2. Rotate the lifting eyes so they are accessible.
3. Loop the slings through, or attach the hooks to, the
lifting eyes.
4. Hoist the bender.
The bender head has two bending positions — vertical

and horizontal. To change the bender head position:
1. Pull out the bender head pivot lock knob. It may be
necessary to twist the knob clockwise until the pin
clears the frame.
2. Pivot the bending head to the desired bending
position.
3. Push the bender head pivot lock knob back into
position so that the pin is fully engaged in the hole.
4. Twist the pivot lock knob counterclockwise until you
feel some resistance. Do not tighten it.
Lowering the Jack Screws
The bender is equipped with four jack screws. To park
the bender at the jobsite, use the 5/16" 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.
854 Quad Bender
Operation
Do not use this tool in a hazard- Do not operate the bender while wearing loose cloth-
ous environment. Hazards include ing. Loose clothing can get caught in moving parts.
flammable liquids, gases, or other Failure to observe this warning could result in severe
materials. Using this tool in a hazard- injury or death.
ous environment can result in a fire
or explosion.
1. Mark the conduit.
Failure to observe this warning will
result in severe injury or death. • 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.
Electric shock hazard: • For a higher level of precision, see the Special
Bending Information section of this manual. This
• Connect the power cord to a
section is based on measurements carried out to
120 volt, 20 amp receptacle on a
two decimal places.
ground fault protected circuit only.
See Grounding Instructions. 2. Turn the power switch/circuit breaker to ON.
• Do not modify the power cord or 3. Use the shoe selection switch on the side of the
plug. bender to select the proper shoe (1/2" to 1-14" shoe
or 1-1/2" to 2" shoe). Press BEND or UNLOAD until
• Inspect the power cord before
the pointer of the selected shoe is 5° to 10° before
use. Repair or replace the cord if
the 0° starting point.
damaged.
4. Insert the conduit into the proper shoe groove and
• Disconnect the unit from power
hook (green hooks indicate IMC, rigid, and sched-
before servicing.
ule 40 pipe; silver hooks indicate EMT). Load the
Failure to observe these warnings conduit so that the bending mark is aligned with the
could result in severe injury or death. front edge of the shoe hook.
• If bending 1/2" to 1/14" conduit, use the roller
support unit as explained under Operation.
• If bending 1-1/2" to 2" EMT, IMC or rigid alu-
Wear eye protection when operating minum, use the roller support unit and set the
or servicing this tool. squeeze as explained under Operation.
Failure to wear eye protection could • If bending 1-1/2" to 2" rigid steel conduit or
result in serious eye injury from flying schedule 40 pipe, ensure that the roller support
debris. 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.
Pinch points:
b. Release the BEND switch as you approach the
Keep hands away from bending desired angle of bend.
shoe, rollers and conduit when
bender is in use. c. Press BEND momentarily until the bend is
complete.
result in severe injury or death. 7. Unload the bender.
a. Press UNLOAD. The shoe will rotate back and drop
the 1-1/2" to 2" roller support unit, if it was used.
b. Twist the conduit to release it from the hook.
Remove the conduit.
Unplug the bender before changing accessories.
Accidental start-up could result in serious injury. c. Press and hold UNLOAD until the shoe has
rotated back to 0°.
854 Quad Bender
Operation (cont’d)
USING ROLLER SUPPORT UNITS ADJUSTING THE SQUEEZE
Use the roller support units to squeeze the conduit as it When bending 1-1/2" to 2" EMT, IMC, and rigid alumi-
is bent. num conduit, the roller support must be engaged so that
the roller supports the conduit; the pressure against the
Using the 1/2" to 1-1/4" Roller Support Unit conduit is the “squeeze”. Setting the squeeze adjust-
Pivot this roller support upward and into place when ment arm to the vertical position (middle hole) provides
bending all types of 1/2" to 1-1/4" conduit. Pivot the the necessary amount of squeeze for most 1-1/2" to 2"
roller support down for easier loading and unloading. EMT and IMC conduit.
Using the 1-1/2" to 2" Roller Support Unit

Engage this roller support when bending 1-1/2" to 2"
EMT, IMC, and rigid aluminum conduit:
1. Load the conduit.
2. 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:
1. Loosen the adjustment arm screw.
2. Rotate the adjustment arm one position counter-
clockwise to INCREASE the squeeze or one posi-
tion clockwise to DECREASE the squeeze.
Note: Decrease the squeeze by three settings when
bending rigid aluminum conduit.
3. 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.
854 Quad Bender
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 suc-

cessive 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:
d θ = angle of bend
a
a 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 — the distance between the two legs of

an offset bend, measured perpendicular to the two legs; also
Offset Height
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 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
854 Quad Bender
Bending Instructions
Single Bends (Stubs and Kicks) 4. Align Bending Mark 1 with the front edge of the
1. Measure the length of the required stub. hook and bend the conduit.
2. See the Minimum Stub on the Deduct Table. The Note: When the operator presses UNLOAD, the conduit
required stub must be equal to or longer than the may spring back a few degrees. Compensate by over-
Minimum Stub. bending as shown in the Scale Reading Table.
3. Measure and mark the stub length on the conduit. STUB
This is the Stub Length Mark. Subtract the Deduct STUB LENGTH LENGTH
from this mark and make a new mark. This is MARK
Bending Mark 1.
Deduct Table BENDING DEDUCT

MARK 1
EMT IMC/Rigid
Conduit
Size Deduct Miminum Deduct Minimum
Stub Stub BENDING
MARK 1
1/2" 7-1/2 9-1/2 7-1/2 9-1/2
STUB LENGTH
3/4" 9 11 9 11
1" 11 13 11 13 STUB
LENGTH
1-1/4" 13-5/8 15-5/8 13-5/8 15-5/8
MARK
1-1/2" 14-7/8 16-7/8 14-7/8 16-7/8
2" 16-3/8 18-3/8 16-1/8 18-1/8
Scale Reading Table

Conduit Size Conduit Type Start (0°) 15° 22-1/2° 30° 45° 60° 90°
EMT 1 16-1/2 24 31-1/2 46-1/2 61-1/2 91-1/2
IMC 2-1/2 17-1/2 25-1/2 33 48 63-1/2 93-1/2
1/2" RIG 1 16-1/2 24 31-1/2 46-1/2 61-1/2 91-1/2
AL 1 16 23-1/2 31 46-1/2 61-1/2 91-1/2
PVC 1-1/2 16-1/2 24 31-1/2 46-1/2 61-1/2 91-1/2
EMT 1 16 24 31-1/2 46-1/2 62 92-1/2
IMC 1 16-1/2 24 31-1/2 47 62 92-1/2
3/4" RIG 1/2 15-1/2 23 30-1/2 45-1/2 60-1/2 90-1/2
AL 1/2 15-1/2 23-1/2 31 46 61-1/2 92
PVC 0 15 22-1/2 30 45 60 90
EMT 0 15 22-1/2 30 45-1/2 60-1/2 90-1/2
IMC 2 17 24-1/2 32 47 62 92-1/2
1" RIG 1 16 23-1/2 31 46 61 91
AL 1/2 15-1/2 23-1/2 31 46 61-1/2 91-1/2
PVC 1/2 15-1/2 23 30-1/2 45-1/2 60-1/2 90-1/2
EMT 1 16 23-1/2 31-1/2 46-1/2 61-1/2 92
IMC 2 17-1/2 25 32-1/2 47-1/2 62-1/2 92-1/2
1-1/4" RIG 1 16 23-1/2 31 46 60-1/2 90-1/2
AL 1-1/2 16-1/2 24 31-1/2 46-1/2 61-1/2 91-1/2
PVC 1/2 15-1/2 23 30-1/2 45-1/2 60-1/2 90-1/2
EMT 1 16 24 31-1/2 46-1/2 61-1/2 92
IMC 2 17 25 32-1/2 47-1/2 63 93-1/2
1-1/2" RIG 0 15 22-1/2 30 45 60 90-1/2
AL 1 16 23-1/2 31 46 61-1/2 91-1/2
PVC 1/2 16 23-1/2 31 46 61 91
EMT 1/2 15 22-1/2 30 45 59-1/2 89
IMC 3-1/2 18-1/2 26 33-1/2 48-1/2 63-1/2 94
2" RIG 1 16 23-1/2 31 45-1/2 60-1/2 90-1/2
AL 2 17 24-1/2 32 47 61-1/2 91-1/2
PVC 2 17 24-1/2 31-1/2 46-1/2 61-1/2 91-1/2
854 Quad Bender
Bending Instructions (cont’d)

Offsets BENDING
START OF BEND MARK 2
1. Measure the height and length of the
obstruction. Select the angle to be used.
2. Refer to the X Table for the X dimension, X
and refer to the Offset Table for the center- BENDING
CENTER TO CENTER
MARK 1
to-center distance.
Note: If the center-to-center distance is not
shown, calculate it by using the multipliers
shown in the Offset Table.
3. Mark the conduit as shown. START OF BEND
4. Insert the conduit into the bender. Align X
Bending Mark 1 with the front edge of the
hook and bend the conduit.
5. Without removing the conduit from the CE BENDING
bender, align Bending Mark 2 with the front BENDING NT
ER MARK 2
MARK 1
edge of the hook and rotate the conduit TO
CE
180°. Make the second bend. NT
ER
X Table Offset Table

Conduit Size X Finished Angle
1/2" 2-1/2 15° 30° 45°
3/4" 3-1/16 Offset Maximum Center- Maximum Center- Maximum Center-
Conduit to-center Conduit to-center Conduit to-center
1" 3-1/16
Size Size Size
1-1/4" 4
2 3/4 7-3/4
1-1/2" 4-3/4
4 1-1/2 15-7/16 3/4 7-15/16
2" 4-3/4
6 2 23-3/16 1 11-15/16 1/2 8-5/16
8 2 30-7/8 1-1/2 15-15/16 1 11-1/16
10 2 38-5/8 2 19-15/16 1-1/4 13-13/16
12 2 46-3/8 2 23-15/16 1-1/2 16-5/8
14 2 54-1/16 2 27-15/16 2 19-7/16
16 2 61-13/16 2 31-15/16 2 22-1/4
18 2 69-9/16 2 35-15/16 2 25-1/16
20 2 77-1/4 2 39-15/16 2 27-15/16
22 2 85 2 43-15/16 2 30-3/4
854 Quad Bender
Special Bending Information

The Special Bending Information section and the 4. In the row at the top of the page, find the height of
Special Bending Information Chart are used together for the obstruction. Under the height, find the corre-
making very precise bends. sponding L1 dimension.
The Special Bending Information Chart is divided into 5. Mark the conduit as shown. Bend the conduit.
sections by the size and type of conduit. Each section Note: After the first bend, do not remove the
contains dimensions (such as Y, L1, L2, and Z) that conduit from the bender. Advance the conduit until
correspond to the illustrations. The top row of the the second bending mark is aligned with the front
Special Bending Information Chart shows some of the edge of the hook, rotate the conduit 180°, and make
typical heights (2", 4", 6", etc), which correspond to the the second bend.
heights in the illustrations.
START OF
SINGLE BENDS (Stubs and Kicks) FIRST BEND
1. Select the size and type of conduit. Determine the

height of the stub or kick and the angle to be used. LENGTH
HEIGHT
2. Find the corresponding section of the Special
Bending Information Chart.
ANGLE
3. In the row at the top of the page, find the height of
the stub. Under the height, find the corresponding
Y dimension.
LENGTH – X L1
4. Mark the conduit as shown. Bend the conduit.
BENDING BENDING
HEIGHT MARK 1 MARK 2
ANGLE
Offsets — Working Toward an Obstruction
1. Select the size and type of conduit. Measure the
Y height of the obstruction and the distance labeled
LENGTH TO END OF SECOND BEND. Determine
the angle to be used.
MARK 2. Find the corresponding section of the Special
OFFSETS
An offset is used to route the conduit around an the obstruction. Under the height, find the corre-
obstruction. To make an offset, two equal bends are sponding L1 and Z dimensions.
required. The distance between the two bends is the
center-to-center distance.
Note: After the first bend, do not remove the
When working past an obstruction, it is necessary to
conduit from the bender. Advance the conduit until
determine the location of the first bend. The center-to-
the second bending mark is aligned with the front
center distance is then used to measure and mark the
edge of the hook, rotate the conduit 180°, and make
distance to the second bend.
the second bend.
When working toward an obstruction, it is necessary to LENGTH TO END OF SECOND BEND
determine the location of the second bend. The center-
to-center distance is then used to measure and mark
the distance to the first bend.
HEIGHT
Offsets — Working Past an Obstruction

1. Select the size and type of conduit. Measure the ANGLE
height of the obstruction and the distance labeled
LENGTH. Determine the angle to be used.
2. Find the X dimension in the X Table under Bending LENGTH – Z L1
Instructions. Subtract X from the LENGTH and mark
the conduit, as shown.
3. Find the corresponding section of the Special BENDING BENDING
Bending Information Chart. MARK 1 MARK 2
854 Quad Bender
Special Bending Information (cont’d)

THREE-BEND SADDLE FOUR-BEND SADDLE
A three-bend saddle is used to route the conduit around 1. Select the size and type of conduit. Measure the
an obstruction. To make a three-bend saddle, three distances labeled LENGTH, STRAIGHT SECTION,
bends are required; the first and third bends are an and HEIGHT. Determine the angle to be used.
equal number of degrees; the second bend is twice that 2. Find the corresponding section of the Special
number of degrees. Bending Information Chart.
1. Select the size and type of conduit. Measure the 3. In the row at the top of the page, find the height of
height of the obstruction and the distance labeled the obstruction. Under the height, find the corre-
LENGTH TO CENTER. Determine the angle to be sponding L1, L2 and Z dimensions.
used.
Note: The “angle to be used” is the first and third
angle of the saddle (not the second), as illustrated. STRAIGHT
LENGTH
Refer to this angle when looking up the correspond- SECTION
ing information in the Special Bending Information
Chart.
2. Find the corresponding section of the Special HEIGHT
ANGLE
the obstruction. Under the height, find the corre- L2 + STRAIGHT SECTION
sponding L1, L2 and Z dimensions.
LENGTH – Z L1 L1
Note: After the first bend, do not remove the
conduit from the bender. Advance the conduit until BENDING BENDING BENDING BENDING
MARK 1 MARK 2 MARK 3 MARK 4
the second bending mark is aligned with the front
edge of the hook, rotate the conduit 180°, and make
the second bend. Then advance the conduit to the U-BENDS
third bending mark, rotate the conduit 180° again, 1. Select the size and type of conduit. Measure and
and make the third bend. mark the distances labeled HEIGHT and LENGTH.
2. Find the corresponding section of the Special
LENGTH TO CENTER
3. In the row at the top of the page, find the height
of the illustration. Under the height, find the corre-
sponding L1 and Y dimensions.
HEIGHT
ANGLE
LENGTH
LENGTH – Z L1 L2
BENDING BENDING BENDING

MARK 1 MARK 2 MARK 3
HEIGHT
Y L1
BENDING BENDING
MARK 1 MARK 2
854 Quad Bender
Special Bending Information Chart

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
1/2" EMT
Y 15 3.28 11.01 18.73 26.45 34.18 41.91 53.50 65.09 88.27 134.64
L1 15 7.72 15.45 23.18 30.90 38.63 46.36 57.95 69.54 92.72 139.09
L2 15 8.88 16.61 24.34 32.07 39.79 47.52 59.11 70.70 93.88 140.25
Z 15 11.13 18.60 26.06 33.53 40.99 48.45 59.65 70.85 93.24 138.02
MINIMUM H = 0.95
Y 22.5 .92 6.14 11.37 16.59 21.82 27.05 34.89 42.73 58.40 89.76
L1 22.5 5.20 10.43 15.66 20.88 26.11 31.33 39.17 47.01 62.69 94.05
L2 22.5 6.95 12.17 17.40 22.63 27.85 33.08 40.92 48.76 64.44 95.79
Z 22.5 9.09 13.92 18.75 23.58 28.41 33.24 40.48 47.72 62.21 91.18
MINIMUM H = 1.63
Y 30 3.60 7.60 11.60 15.60 19.60 25.60 31.60 43.60 67.60
L1 30 7.95 11.95 15.95 19.95 23.95 29.95 35.95 47.95 71.95
L2 30 10.27 14.27 18.27 22.27 26.27 32.27 38.27 50.27 74.27
Z 30 11.81 15.27 18.74 22.20 25.66 30.86 36.06 46.45 67.23
MINIMUM H = 2.44
Y 45 3.65 6.47 9.30 12.13 16.37 20.61 29.10 46.07
L1 45 8.29 11.12 13.95 16.78 21.02 25.26 33.75 50.72
L2 45 11.78 14.61 17.44 20.27 24.51 28.75 37.24 54.21
Z 45 12.18 14.18 16.18 18.18 21.18 24.18 30.18 42.18
MINIMUM H = 4.37
Y 60 3.77 6.08 8.38 11.85 15.31 22.24 36.10
L1 60 8.76 11.07 13.38 16.84 20.31 27.24 41.09
L2 60 13.41 15.72 18.03 21.49 24.96 31.89 45.74
Z 60 12.25 13.40 14.56 16.29 18.02 21.48 28.41
MINIMUM H = 6.61
Y 90 4.71 7.71 10.71 16.71 28.71
L1 90 10.09 13.09 16.09 22.09 34.09
L2 90 17.07 20.07 23.07 29.07 41.07
Z 90 11.38 11.38 11.38 11.38 11.38
MINIMUM H = 11.38
3/4" EMT
Y 15 2.07 9.80 17.53 25.26 32.98 40.71 52.30 63.89 87.08 133.44
L1 15 7.72 15.45 23.17 30.90 38.63 46.36 57.95 69.54 92.72 139.08
L2 15 9.20 16.93 24.66 32.39 40.11 47.84 59.43 71.02 94.20 140.57
Z 15 12.08 19.55 27.01 34.47 41.94 49.40 60.60 71.79 94.19 138.97
MINIMUM H = 1.20
Y 22.5 5.00 10.22 15.45 20.67 25.90 33.74 41.58 57.26 88.62
L1 22.5 10.42 15.65 20.88 26.10 31.33 39.17 47.01 62.69 94.04
L2 22.5 12.65 17.88 23.10 28.33 33.56 41.39 49.23 64.91 96.27
Z 22.5 15.04 19.87 24.69 29.52 34.35 41.59 48.84 63.32 92.29
MINIMUM H = 2.06
Y 30 6.43 10.43 14.43 18.43 24.43 30.43 42.43 66.43
L1 30 7.93 11.93 15.93 19.93 23.93 29.93 35.93 47.93 71.93
L2 30 10.90 14.90 18.90 22.90 26.90 32.90 38.90 50.90 74.90
Z 30 13.09 16.56 20.02 23.48 26.95 32.14 37.37 47.73 68.52
MINIMUM H = 3.08
Y 45 2.36 5.19 8.02 10.85 15.09 19.33 27.82 44.79
L1 45 8.24 11.07 13.90 16.73 20.97 25.21 33.70 50.67
L2 45 12.69 15.52 18.35 21.18 25.42 29.67 38.15 55.12
Z 45 13.82 15.82 17.82 19.82 22.82 25.82 31.82 43.82
MINIMUM H = 5.53
Y 60 4.62 6.93 10.39 13.85 20.78 34.64
L1 60 10.94 13.25 16.71 20.18 27.10 40.96
L2 60 16.88 19.18 22.65 26.11 33.04 46.90
Z 60 15.45 16.60 18.33 20.06 23.53 30.46
MINIMUM H = 8.38
Y 90 5.74 8.74 14.74 26.74
L1 90 12.57 15.57 21.57 33.57
L2 90 21.47 24.47 30.47 42.47
Z 90 14.47 14.47 14.47 14.47
MINIMUM H= 14.47
854 Quad Bender
Special Bending Information Chart (cont’d)

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
1" EMT
Y 15 1.35 9.07 16.80 24.53 32.26 39.98 51.58 63.17 86.35 132.71
L1 15 7.72 15.44 23.17 30.90 38.63 46.35 57.94 69.54 92.72 139.08
L2 15 9.60 17.33 25.06 32.79 40.51 48.24 59.83 71.42 94.61 140.97
Z 15 12.55 20.02 27.48 34.94 42.41 49.87 61.07 72.27 94.66 139.44
MINIMUM H = 1.32
Y 22.5 4.31 9.54 14.77 19.99 25.22 33.06 40.90 56.58 87.93
L1 22.5 10.42 15.64 20.87 26.09 31.32 39.16 47.00 62.68 94.04
L2 22.5 13.25 18.47 23.70 28.93 34.15 41.99 49.83 65.51 96.87
Z 22.5 15.72 20.54 25.37 30.20 35.03 42.27 49.51 64.00 92.97
MINIMUM H = 2.32
Y 30 1.72 5.72 9.72 13.72 17.72 23.72 29.72 41.72 65.72

L1 30 7.91 11.91 15.91 19.91 23.91 29.91 35.91 47.91 71.91
L2 30 11.69 15.69 19.69 23.69 27.69 33.69 39.69 51.69 75.69
Z 30 13.98 17.45 20.91 24.37 27.84 33.03 38.23 48.62 69.41
MINIMUM H = 3.53
Y 45 4.32 7.15 9.97 14.22 18.46 26.94 43.91
L1 45 11.00 13.83 16.66 20.90 25.15 33.63 50.60
L2 45 16.67 19.49 22.32 26.57 30.81 39.29 56.26
Z 45 17.16 19.16 21.16 24.16 27.16 33.16 45.16
MINIMUM H = 6.48
Y 60 3.52 5.83 9.30 12.76 19.69 33.55
L1 60 10.77 13.08 16.55 20.01 26.94 40.79
L2 60 18.32 20.63 24.10 27.56 34.49 48.34
Z 60 17.29 18.44 20.18 21.91 25.37 32.30
MINIMUM H = 9.97
Y 90 7.02 13.02 25.02
L1 90 14.91 20.91 32.91
L2 90 26.23 32.23 44.23
Z 90 17.61 17.61 17.61
MINIMUM H = 17.61
1-1/4" EMT
Y 15 7.41 15.13 22.86 30.59 38.31 49.91 61.50 84.68 130.04
L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08
L2 15 10.09 17.82 25.55 33.27 41.00 48.73 60.32 71.91 95.09 141.46
Z 15 13.79 21.26 28.72 36.18 43.65 51.11 62.31 73.50 95.90 140.68
MINIMUM H = 1.65
Y 22.5 2.74 7.96 13.19 18.42 23.64 31.48 39.32 55.00 86.36
L1 22.5 10.41 15.63 20.86 26.08 31.31 39.15 46.99 62.67 94.03
L2 22.5 13.97 19.20 24.42 29.65 34.88 42.72 50.56 66.23 97.59
Z 22.5 17.21 22.03 26.86 31.69 36.52 43.76 51.01 65.49 94.46
MINIMUM H = 2.89
Y 30 4.12 8.12 12.12 16.12 22.12 28.12 40.12 64.12
L1 30 11.89 15.89 19.89 23.89 29.89 35.89 47.89 71.89
L2 30 16.64 20.64 24.64 28.64 34.64 40.64 52.64 76.64
Z 30 19.20 22.66 26.12 29.59 34.78 39.98 50.37 71.16
MINIMUM H = 4.40
Y 45 2.55 5.38 8.20 12.45 16.69 25.18 42.15
L1 45 13.75 16.58 20.82 25.07 33.55 50.52
L2 45 20.88 23.71 27.95 32.20 40.68 57.65
Z 45 21.46 23.46 26.46 29.46 35.46 47.46
MINIMUM H = 8.10
Y 60 1.50 3.81 7.27 10.73 17.66 31.52
L1 60 16.34 19.81 26.74 40.59
L2 60 25.85 29.32 36.25 50.10
Z 60 23.08 24.81 28.28 35.21
MINIMUM H = 12.49
Y 90 1.23 4.23 10.23 22.23
L1 90 20.10 32.10
L2 90 34.37 46.37
Z 90 22.10 22.10
MINIMUM H = 22.10
854 Quad Bender

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
1-1/2" EMT
Y 15 5.56 13.29 21.01 28.74 36.47 48.06 59.65 82.83 129.20
L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08
L2 15 10.02 17.75 25.48 33.20 40.93 48.66 60.25 71.84 95.02 141.39
Z 15 15.16 22.62 30.09 37.55 45.02 52.48 63.68 74.87 97.26 142.05
MINIMUM H = 1.99
Y 22.5 1.05 6.28 11.50 16.73 21.96 29.80 37.64 53.31 84.67
L1 22.5 10.41 15.63 20.86 26.09 31.31 39.15 46.99 62.67 94.03
L2 22.5 13.87 19.09 24.32 29.55 34.77 42.61 50.95 66.13 97.49
Z 22.5 18.54 23.37 28.19 33.02 37.85 45.09 52.34 66.82 95.79
MINIMUM H = 3.40
Y 30 2.52 6.52 10.52 14.52 20.52 26.52 38.52 62.52
L1 30 11.89 15.89 19.89 23.89 29.89 35.89 47.89 71.89
L2 30 16.50 20.50 24.50 28.50 34.50 40.50 52.50 76.50
Z 30 20.49 23.95 27.42 30.88 36.08 41.27 51.67 72.45
MINIMUM H = 5.05
Y 45 1.06 3.89 6.72 10.96 15.20 23.69 40.66
L1 45 13.77 16.60 20.84 25.08 33.57 50.54
L2 45 20.68 23.51 27.75 32.00 40.48 57.45
Z 45 22.67 24.67 27.67 30.67 36.67 48.67
MINIMUM H = 8.96
Y 60 2.39 5.85 9.32 16.25 30.10
L1 60 16.39 19.86 26.79 40.64
L2 60 25.60 28.06 35.89 49.85
Z 60 24.21 25.94 29.40 36.33
MINIMUM H = 13.46
Y 90 2.95 8.95 20.95
L1 90 20.22 32.22
L2 90 34.06 46.06
Z 90 23.00 23.00
MINIMUM H = 23.00
2" EMT
Y 15 4.42 12.15 19.88 27.61 35.33 46.92 58.51 81.70 128.06
L1 15 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.71 139.08
L2 15 18.00 25.73 33.46 41.18 48.91 60.50 72.09 95.27 141.64
Z 15 23.00 30.47 37.93 45.40 52.86 64.06 75.25 97.64 142.43
MINIMUM H = 2.09
Y 22.5 .14 5.36 10.59 15.82 21.04 28.88 36.72 52.40 83.76
L1 22.5 10.40 15.63 20.86 26.08 31.31 39.15 46.99 62.67 94.02
L2 22.5 14.24 19.47 24.70 29.92 35.15 42.99 50.83 66.51 97.86
Z 22.5 19.05 23.88 28.70 33.53 38.36 45.60 52.85 67.33 96.30
MINIMUM H = 3.59
Y 30 1.68 5.68 9.68 13.68 19.68 25.68 37.68 61.68
L1 30 11.88 15.88 19.88 23.88 29.88 35.88 47.88 71.88
L2 30 17.00 21.00 25.00 29.00 35.00 41.00 53.00 77.00
Z 30 21.13 24.60 28.06 31.53 36.72 41.92 52.31 73.09
MINIMUM H = 5.37
Y 45 .21 3.04 5.87 10.11 14.35 22.84 39.81
L1 45 13.73 16.56 20.80 25.05 33.53 50.50
L2 45 21.40 24.23 28.47 32.72 41.20 58.17
Z 45 23.60 25.60 28.60 31.60 37.60 49.60
MINIMUM H = 9.61
Y 60 1.44 4.91 8.37 15.30 29.15
L1 60 16.27 19.73 26.66 40.52
L2 60 26.51 29.96 36.80 50.76
Z 60 25.45 27.19 30.65 37.58
MINIMUM H = 14.54
Y 90 1.62 7.62 19.62
L1 90 31.80
L2 90 47.16
Z 90 25.06
MINIMUM H= 25.06
854 Quad Bender

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
1/2" IMC/Rigid
Y 15 3.03 10.76 18.48 26.21 33.94 41.67 53.26 64.85 88.03 134.39
L1 15 7.72 15.45 23.18 30.90 38.63 46.36 57.95 69.54 92.72 139.09
L2 15 8.87 16.59 24.32 32.05 39.78 47.50 59.10 70.69 93.87 140.23
Z 15 11.12 18.58 26.05 33.51 40.97 48.44 59.63 70.83 93.22 138.01
MINIMUM H = 0.95
Y 22.5 .77 5.98 11.21 16.44 21.66 26.89 34.73 42.57 58.25 89.60
L1 22.5 5.20 10.43 15.66 20.88 26.11 31.34 39.17 47.01 62.69 94.05
L2 22.5 6.92 12.15 17.38 22.60 27.83 33.06 40.89 48.73 64.41 95.77
Z 22.5 9.07 13.90 18.73 23.56 28.38 33.21 40.46 47.70 62.18 91.15
MINIMUM H = 1.62
Y 30 3.49 7.49 11.49 15.49 19.49 25.49 31.49 43.49 67.49
L1 30 7.95 11.95 15.95 19.95 23.95 29.95 35.95 47.95 71.95
L2 30 10.24 14.24 18.24 22.24 26.24 32.24 38.24 50.24 74.24
Z 30 11.78 15.24 18.70 22.17 25.63 30.83 36.02 46.42 67.20
MINIMUM H = 2.42
Y 45 3.59 6.41 9.23 12.06 16.30 20.55 29.03 46.00
L1 45 8.30 11.13 13.95 16.78 21.02 25.27 33.75 50.72
L2 45 11.74 14.57 17.39 20.22 24.46 28.71 37.19 54.16
Z 45 12.13 14.13 16.13 18.13 21.13 24.13 30.13 42.13
MINIMUM H = 4.33
Y 60 1.42 3.73 6.04 8.34 11.81 15.27 22.20 36.06
L1 60 8.77 11.08 13.39 16.85 20.31 27.24 41.10
L2 60 13.35 15.66 17.97 21.44 24.90 31.83 45.69
Z 60 12.18 13.33 14.49 16.22 17.95 21.41 28.34
MINIMUM H = 6.55
Y 90 .71 2.71 4.71 7.71 10.71 16.70 28.70
L1 90 10.12 13.12 16.12 22.12 34.12
L2 90 17.00 20.00 23.00 29.00 41.00
Z 90 11.26 11.26 11.26 11.26 11.26
MINIMUM H = 11.26
3/4" IMC/Rigid
Y 15 1.86 9.58 17.31 25.04 32.77 40.49 52.08 63.68 86.86 133.22
L1 15 7.72 15.45 23.17 30.90 38.63 46.36 57.95 69.54 92.72 139.08
L2 15 9.19 16.91 24.64 32.37 40.09 47.82 59.41 71.00 94.19 140.55
Z 15 12.06 19.53 26.89 34.46 41.92 49.38 60.58 71.78 94.17 138.95
MINIMUM H = 1.19
Y 22.5 4.85 10.08 15.31 20.53 25.76 33.60 41.44 57.12 88.47
L1 22.5 10.42 15.65 20.88 26.10 31.33 39.17 47.01 62.69 94.04
L2 22.5 12.62 17.85 23.08 28.30 33.53 41.37 49.21 64.89 96.24
Z 22.5 15.01 19.84 24.67 29.49 34.32 41.57 48.81 63.29 92.26
MINIMUM H = 2.05
Y 30 2.33 6.33 10.33 14.33 18.33 24.33 30.33 42.33 66.33
L1 30 7.93 11.93 15.93 19.93 23.93 29.93 35.93 47.93 71.93
L2 30 10.86 14.86 18.86 22.86 26.86 32.86 38.86 50.86 74.86
Z 30 13.05 16.52 19.98 23.45 26.91 32.11 37.30 47.70 68.48
MINIMUM H = 3.06
Y 45 2.31 5.13 7.96 10.79 15.03 19.28 27.76 44.73
L1 45 8.24 11.07 13.90 16.73 20.97 25.21 33.70 50.67
L2 45 12.64 15.47 18.30 21.13 25.37 29.61 38.10 55.07
Z 45 13.76 15.76 17.76 19.76 22.76 25.76 31.76 43.76
MINIMUM H = 5.49
Y 60 2.28 4.59 6.90 10.36 13.83 20.75 34.61
L1 60 10.94 13.25 16.72 20.18 27.11 40.97
L2 60 16.81 19.12 22.58 26.05 32.98 46.83
Z 60 15.36 16.52 18.25 19.88 23.45 30.38
MINIMUM H = 8.31
Y 90 .76 2.76 5.76 8.76 14.76 26.76
L1 90 12.60 15.60 21.60 33.60
L2 90 21.39 24.39 30.39 42.39
Z 90 14.33 14.33 14.33 14.33
MINIMUM H = 14.33
854 Quad Bender

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
1" IMC/Rigid
Y 15 1.08 8.81 16.52 24.25 31.97 39.70 51.29 62.88 86.07 132.43
L1 15 7.72 15.44 23.17 30.90 38.63 46.35 57.94 69.54 92.72 139.08
L2 15 9.59 17.32 25.04 32.77 40.50 48.23 59.82 71.41 94.59 140.95
Z 15 12.53 20.00 27.46 34.93 42.39 49.86 61.05 72.25 94.64 139.43
MINIMUM H = 1.31
Y 22.5 4.13 9.35 14.58 19.81 25.03 32.87 40.71 56.39 87.75
L1 22.5 10.42 15.64 20.87 26.09 31.32 39.16 47.00 62.68 94.04
L2 22.5 13.22 18.45 23.68 28.90 34.13 41.97 49.81 65.49 96.84
Z 22.5 15.69 20.52 25.35 30.18 35.01 42.25 49.49 63.98 92.95
MINIMUM H = 2.31
Y 30 1.58 5.58 9.58 13.58 17.58 23.58 29.58 41.58 65.58
L1 30 7.91 11.91 15.91 19.91 23.91 29.91 35.91 47.91 71.91
L2 30 11.66 15.66 19.66 23.66 27.66 33.66 39.66 51.66 75.66
Z 30 13.95 17.41 20.88 24.34 27.81 33.00 38.20 48.59 69.38
MINIMUM H = 3.51
Y 45 1.42 4.24 7.06 9.89 14.14 18.38 26.86 43.83
L1 45 11.01 13.83 16.66 20.91 25.15 33.63 50.60
L2 45 16.62 19.45 22.28 26.52 30.76 39.25 56.22
Z 45 17.11 19.11 21.11 24.11 27.11 33.11 45.11
MINIMUM H = 6.44
Y 60 1.17 3.48 5.79 9.25 12.71 19.64 33.49
L1 60 10.78 13.09 16.55 20.02 26.94 40.80
L2 60 18.27 20.58 24.04 27.50 34.43 48.29
Z 60 17.22 18.37 20.11 21.84 25.30 32.23
MINIMUM H = 9.91
Y 90 1.01 4.01 7.01 13.01 25.01
L1 90 14.93 20.93 32.93
L2 90 26.16 32.16 44.16
Z 90 17.49 17.49 17.49
MINIMUM H = 17.49
1-1/4" IMC/Rigid
Y 15 7.15 14.87 22.60 30.33 38.06 49.65 61.24 84.42 130.78
L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08
L2 15 10.07 17.80 25.53 33.25 40.98 48.71 60.30 71.89 95.07 141.44
Z 15 13.77 21.24 28.70 36.17 43.63 51.09 62.29 73.49 95.88 140.66
MINIMUM H = 1.63
Y 22.5 2.57 7.80 13.02 18.25 23.47 31.31 39.15 54.83 86.19
L1 22.5 10.41 15.63 20.86 26.09 31.31 39.15 46.99 62.67 94.03
L2 22.5 13.94 19.17 24.40 29.62 34.85 42.69 50.53 66.21 97.56
Z 22.5 17.18 22.01 26.84 31.66 36.49 43.73 50.98 65.46 94.43
MINIMUM H = 2.88
Y 30 4.00 8.00 12.00 16.00 22.00 28.00 40.00 64.00
L1 30 11.89 15.89 19.89 23.89 29.89 35.89 47.89 71.89
L2 30 16.61 20.61 24.61 28.61 34.61 40.61 52.61 76.61
Z 30 19.16 22.62 26.09 29.55 34.75 39.94 50.33 71.12
MINIMUM H = 4.38
Y 45 2.48 5.31 8.14 12.38 16.62 25.11 42.08
L1 45 13.75 16.58 20.83 25.07 33.55 50.52
L2 45 20.83 23.66 27.90 32.14 40.63 57.60
Z 45 21.40 23.40 26.40 29.40 35.40 47.40
MINIMUM H = 8.06
Y 60 1.46 3.77 7.23 10.69 17.62 31.48
L1 60 16.35 19.82 26.74 40.60
L2 60 25.79 29.25 36.18 50.04
Z 60 23.00 24.73 28.20 35.13
MINIMUM H = 12.42
Y 90 1.23 4.23 10.23 22.23
L1 90 20.13 32.13
L2 90 34.29 46.29
Z 90 21.96 21.96
MINIMUM H = 21.96
854 Quad Bender

DIM ANGLE 2" 4" 6" 8" 10" 12" 15" 18" 24" 36"
1-1/2" IMC/Rigid
Y 15 5.30 13.03 20.75 28.48 36.21 47.80 59.39 82.57 128.94
L1 15 7.71 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.72 139.08
L2 15 9.94 17.67 25.39 33.12 40.85 48.58 60.17 71.76 94.94 141.31
Z 15 15.09 22.56 30.02 37.49 44.95 52.41 63.61 74.81 97.20 141.98
MINIMUM H = 1.97
Y 22.5 .90 6.13 11.36 16.58 21.81 29.65 37.49 53.17 84.52
L1 22.5 10.41 15.64 20.86 26.09 31.31 39.15 46.99 62.67 94.03
L2 22.5 13.75 18.97 24.20 29.43 34.65 42.49 50.33 66.01 97.37
Z 22.5 18.44 23.27 28.09 32.92 37.75 44.89 52.24 66.72 95.69
MINIMUM H = 3.36
Y 30 2.44 6.44 10.44 14.44 20.44 26.44 38.44 62.44
L1 30 11.90 15.90 19.90 23.90 29.90 35.90 47.90 71.90
L2 30 16.35 20.35 24.35 28.35 34.35 40.35 52.35 76.35
Z 30 20.35 23.82 27.28 30.75 35.94 41.14 51.53 72.32
MINIMUM H = 4.98
Y 45 1.06 3.88 6.71 10.96 15.20 23.68 40.65
L1 45 13.78 16.60 20.85 25.09 33.58 50.55
L2 45 20.50 23.33 27.57 31.81 40.30 57.27
Z 45 22.47 24.47 27.47 30.47 36.47 48.47
MINIMUM H = 8.82
Y 60 2.45 5.91 9.38 16.30 30.16
L1 60 16.41 19.87 26.80 40.66
L2 60 25.36 28.83 35.76 49.61
Z 60 23.92 25.65 29.12 36.04
MINIMUM H = 13.21
Y 90 3.12 9.12 21.12
L1 90 20.33 32.33
L2 90 33.77 45.77
Z 90 22.50 22.50
MINIMUM H = 22.50
2" IMC/Rigid
Y 15 4.15 11.87 19.60 27.33 35.06 46.65 58.24 81.42 127.78
L1 15 15.44 23.17 30.90 38.62 46.35 57.94 69.53 92.71 139.08
L2 15 17.80 25.62 33.35 41.08 48.80 60.40 71.99 95.17 141.53
Z 15 22.90 30.36 37.82 45.29 52.75 63.95 75.15 97.54 142.32
MINIMUM H = 2.06
Y 22.5 5.22 10.45 15.67 20.90 28.74 36.58 52.26 83.61
L1 22.5 10.40 15.63 20.86 26.08 31.31 39.15 46.99 62.67 94.02
L2 22.5 14.09 19.31 24.54 29.76 35.00 42.83 50.67 66.35 97.71
Z 22.5 18.89 23.71 28.54 33.37 38.20 45.44 52.69 67.17 96.14
MINIMUM H = 3.53
Y 30 1.62 5.62 9.62 13.62 19.62 25.62 37.62 61.62
L1 30 11.88 15.88 19.88 23.88 29.88 35.88 47.88 71.88
L2 30 16.79 20.79 24.79 28.79 34.79 40.79 52.79 76.79
Z 30 20.92 24.38 27.84 31.31 36.50 41.70 52.09 72.88
MINIMUM H = 5.26
Y 45 .26 3.08 5.91 10.16 14.40 22.88 39.85
L1 45 13.74 16.56 20.81 25.05 33.53 50.50
L2 45 21.10 23.93 28.17 32.42 40.80 57.87
Z 45 23.27 25.27 28.27 31.27 37.27 49.27
MINIMUM H = 9.38
Y 60 1.58 5.04 8.50 15.43 29.29
L1 60 16.30 19.77 26.70 40.55
L2 60 26.13 29.59 36.52 50.38
Z 60 24.99 26.72 30.18 37.11
MINIMUM H = 14.14
Y 90 1.94 7.94 19.94
L1 90 31.98
L2 90 46.70
Z 90 24.25
MINIMUM H = 24.25
854 Quad Bender
Maintenance
Chain Lubrication and Tension Adjustment
1. Disconnect the bender from the power source.
Electric shock hazard: 2. See the 1-1/2" to 2" Side Exploded View. Remove
the 1-1/2" to 2" shoe (see Changing Shoes in this
Disconnect the unit from power section of the manual).
before servicing.
3. See the Main Exploded View. Remove the screws
Failure to observe this warning could (23) and front chain guard assembly (4).
4. Spray a motorcycle chain lubricant on the inside
of the chain between the sprockets while pressing
UNLOAD. Lubricate the entire length of the chain.
5. Check the amount of slack halfway between the
sprockets. If the chain slack is :
Wear eye protection when operating • More than 25 mm (1"), proceed to step 6.
or servicing this tool. • Less than 25 mm (1"), proceed to step 10.
Failure to wear eye protection could 6. Remove 11 screws (23) and motor guard (5).
result in serious eye injury from flying
debris. 7. Loosen the two motor mounting screws (25) on the
front, and the two on the back, and the nut (22).
8. Torque the eccentric locator (21) to 81 Nm (60 ft-lb).
Schedule Maintain this amount of torque while tightening the
nut (22) and two front screws (25).
Component Maintenance Activity Maintenance Interval 9. Tighten the two rear screws (25).
Lubrication and
Chain
Tension Adjustment
Every 6 months* 10. Assemble in reverse order.
Roller Supports Cleaning and Every 6 months*

Lubrication
1/2" to 1-1/4" Roller Support
Commutator When drive unit
Brushes Replacement performance 1. Disconnect the bender from the power source.
diminishes noticeably
2. Remove support pivot pin (19). Remove roller
* More often if the bender is used in dusty or corrosive environments support (7).
3. Spray a motorcycle chain lubricant through the
3 mm (1/8") diameter hole in each roller. Rotate
each roller to distribute the lubricant.
4. Spray the pivot pin.
5. Wipe away any excess lubricant.
6. Replace the roller support and pivot pin.
854 Quad Bender
Maintenance (cont’d)
1-1/2" to 2" Roller Support 10. Clean off all of the grease and dirt.
1. Disconnect the bender from the power source. 11. Inspect each item. Replace any worn, damaged,
2. Remove the 1-1/2" to 2" shoe (see Changing Shoes or missing items.
in this section of the manual). 12. Lubricate all working surfaces with a high-quality
3. See the 1-1/2" to 2" Roller Support Unit Exploded grease.
View. Use a pair of needlenose pliers to disconnect 13. Replace all components in reverse order, noting the
the springs (104) from the holes in the side of the following:
bender frame beneath the roller support unit.
• On both roller groups: To ease the assembly of
4. See the Main Exploded View. Remove the squeeze the split roller subassemblies, begin by slipping
adjustment arm screw (97) and arm (74). the O-rings onto the side plates. Assemble the
5. Remove the three button head cap screws (96) and split roller subassemblies as shown, then slip the
adapter sleeve (92). O-rings into their correct positions.
6. Place one hand under the support arms (71) to • On the 2" roller group only: After replacing any
support the weight of the roller support unit. split roller components, add or remove shim
Remove the eccentric shaft (91). washers (99, 119, or 150) as needed.
Note: You may need to rotate the eccentric shaft to • On the 1-1/2" roller group: Install the two bel-
remove it. leville washers (100) so that the inside diameters
contact each other.
• Use Loctite® 271 on the two hex head screws
(93). Torque to 55 to 61 Nm (40 to 45 ft-lb).
Pinch points: 14. Position the roller support arms (71) as shown.
Use both hands to hold the two lead Assemble the roller groups to the support arms.
and two tail rollers to prevent the 15. Reinstall the roller support unit to the bender. Keep
rollers from pivoting. one hand under the support arms so they do not
Failure to observe this precaution drop completely below the set screw (107).
could result in injury or property 16. Insert the eccentric shaft (91).
damage. Note: You may need to rotate the eccentric shaft to
get it to seat completely.
7. Lift the roller support subassembly to the left and 17. Install the adapter sleeve (92) and three button head
upward. cap screws (96).
8. On the 1-1/2" roller group: 18. Install the adjustment arm (74) and adjustment arm
screw (97).
• Loosen the sleeve set screw (98) and remove the
1-1/2" pivot roller shaft (86) with grip (90). Remove 19. Attach the springs (104) to the holes in the side of
the sleeve (87). the bender frame beneath the roller support unit.
• Remove two hex head screws (93). Remove the 20. Put the bender in the horizontal bending position.
outer roller plate (75). Adjust the set screw (107), if necessary, so that the
support arms (71) are centered between the front
• Remove the tail roller (84). and back plates. Engage and disengage the roller
• Remove all components of the split roller support unit to be sure that it moves freely.
assembly.
9. On the 2" roller group:
• Loosen the sleeve set screw (98) and press out
the 2" pivot shaft (88). Remove the sleeve (89).
• Remove the hex head screw (93). Remove one
retaining ring (95) from the tail roller shaft (83).
Remove outer roller plate (76).
• Remove the tail roller (82) and center roller (85).
• Remove all components of the split roller
assembly.
854 Quad Bender
Maintenance (cont’d)
Changing Shoes Pointer Accuracy
1. Disconnect the bender from the power source. 1. Loosen the two locking screws (29).
2. Lock the bender head in the vertical bending 2. Move the pointer (30 or 31).
position (see Pivoting the Bender Head in the
3. Tighten the screws.
Transportation and Setup section of this manual).
3. See the 1/2" to 1-1/4" Side Exploded View or the
1-1/2" to 2" Side Exploded View. Use retaining ring Locking Screws
pliers to remove the retaining ring (26) that secures
the shoe.
4. Remove the shoe from the spindle.
Drive lugs closest

to hooks must Commutator Brushes
engage in
these holes. 1. Disconnect the bender from the power source.
Protruding 2. See the Main Exploded View. Remove the 11
Bolts screws (23) and the motor guard (5). Remove the
motor guard.
3. Remove the power cord strain relief (37).
4. Refer to Drive Unit Exploded View. Remove the two
Allen screws and nuts that secure the shroud (6) to
the motor. Remove the shroud.
5. Push in the commutator brush retainer and move it
toward the brush (1) to release it. Unplug the brush
and remove it. Replace the brush if it is less than
6 mm (1/4") long.
6. Repeat step 5 for the other brush.
7. Assemble in reverse order.
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.
854 Quad Bender
Troubleshooting
Problem Probable Cause Probable Remedy
Bender will not operate. No voltage. Check supply voltage circuit

operation.
Check that switch is ON.
Bender operates in wrong direction. Wrong side of bender selected. Set selector switch properly.
Bends are overbent a few degrees. Pointer is adjusted wrong. Loosen pointer locking screws and
rotate clockwise to compensate.
Retighten locking screws.
Too much squeeze on 1-1/2" or 2" Back squeeze off per adjustment
EMT or IMC conduit. instructions.
Unusual conduit characteristics. Adjust pointer or bend to a smaller

angle to compensate.
Bends are underbent a few degrees. Pointer is adjusted wrong. Loosen pointer locking screws and
rotate counterclockwise to compen-
sate. Retighten locking screws.
Too little squeeze on 1-1/2" or 2" Increase squeeze per adjustment

EMT or IMC conduit. instructions.
Unusual conduit characteristics. Adjust pointer or bend to a larger

angle to compensate.
854 Quad Bender
Troubleshooting (cont’d)
The following flow charts show the suggested trouble- Trips circuit breaker
shooting procedures for some bender problems. They
Are the proper support rollers
by no means encompass all possible problems or and shoe groove being used for NO Follow directions in
solutions. the type and size of conduit be- instruction manual.
ing bent?
YES
Is the current on the 115 VAC line NO

Replace circuit
exceeding 20 amps? breaker.
Electric shock hazard:
YES
• Contact with live circuits can result
in severe injury or death. Is the DC current to the motor YES
Replace motor.
• Some troubleshooting steps exceeding 17 amps?
require power to the bender. NO
This type of troubleshooting
step should only be performed When BEND is pressed, is the NO Replace bridge
voltage sent to the motor 20 to 50 rectifier
at authorized Greenlee service volts over the AC line voltage? (918 5997.2).
centers by personnel who are
YES
familiar with safe troubleshooting
procedures. YES
Are connectors corroded? Clean.
could result in severe injury or death. NO
Replace PGU.
Won’t bend Won’t stop

YES
NO Plugged into dead cir- Is the supply line voltage low? Use 115 VAC.
Is 115 VAC measured at
cuit, bad power cord, or
PGU board input? NO
switch is bad or off.
YES Does bender stop when the YES Replace pendant
pendant is unplugged? switch.
Does the green LED on NO
Replace transformer unit.
the I/O board light? NO
YES Replace PGU.

Are metal oxide varistors
YES Replace PGU.
(MOVs) on PGU board
damaged or discolored?
NO Bender only runs in one direction
Does the green LED on NO On 854 move pendant plug to YES
Replace PGU. Replace direction
the PGU light? I/O board. Does bender run both
directions? switch assembly.
YES
NO
Does amber or red LED Unplug pendant or I/O and
NO
on I/O light when BEND check switch for continuity. Does amber or red LED light when NO Check and replace
or UNLOAD is pressed? If ok, replace I/O. switch is pressed? pendant switch.
YES
YES
Does relay on I/O NO Replace I/O.
operate when BEND or When amber or red LED is on, is
12 VDC measured at large relay NO
UNLOAD is pressed? Replace PGU.
coil on PGU (where relay wire
YES unit connects)?
Replace PGU. YES
Replace 918 6645.6 relay.
854 Quad Bender
1/2" to 1-1/4" Side Exploded View
7
24
19
43 Shoe Unit 1/2" to 1-1/4" consists

of 221, 222, 223, 224 and 225
223
225
222
206
224
26
23
213 5 221 225
205
206
204
854 Quad Bender
1-1/2" to 2" Side Exploded View
The Roller Support Unit

exploded view is on
the following page.
3
44 Shoe Unit 1-1/2" to 2" consists

of 224, 226, 227, 228 and 229
228
226
224
227
26
226
91
92
207 229
74 96
97
207 215
232
215
213
854 Quad Bender
1-1/2" to 2" Roller Support Unit Exploded View and Parts List
95
118
89
73 82
98 105
117 85
83
71 104
104 95
84
72
115
80
79
81
79
80
117
76
88
93*
86
116
78
77 99, 119
100 or 150
77 93*
78
98
116
87
94 75
93*
151 101 Torque to 94 Nm (70 ft-lb)
90
50005740 Roller Support Unit consists of:

UPC No. UPC No.
Key 78-3310- Part No. Description Qty Key 78-3310- Part No. Description Qty
71 38221 50382217 Support weldment, roller...................................1 91 38256 50382560 Shaft, eccentric.................................................1
72 00528 50005286 Support weldment, 1-1/2".................................1 92 38251 50382519 Sleeve adapter..................................................1
73 00601 50006010 Support weldment, 2".......................................1 93 50540 90505409 Screw, 7/16-14 x 1.00 hex head........................3
74 38225 50382250 Arm weldment, adjustment................................1 94 00860 50008609 Shaft, 1-1/2" Support........................................1
75 00543 50005430 Plate, 1-1/2" outer roller....................................1 95 54819 90548191 Retaining ring #5100-87...................................2
76 00604 50006045 Plate, 2" outer roller..........................................1 96 54242 90542428 Screw, cap 1/4-20 x .37 button head.................3
77 38254 50382543 Split rollers, 1-1/2"............................................2 97 50224 90502248 Screw, 5/16-18 x 1.00 socket head...................1
78 38264 50382640 Ball, 1-1/2".......................................................2 98 50881 90508815 Screw, 1/4-28 x .25 set.....................................2
79 38255 50382551 Split rollers, 2"..................................................2 99 53918 90539184 Washer, 1.00 x 1.37 x .03 shim.........................1
80 38263 50382632 Ball, 2"..............................................................2 100 54248 90542487 Washer, Belleville 1.362 x .803..........................2
81 38262 50382624 Spacer, 2" roller................................................1 101 39440 50394401 Washer, .62 x 2.00 x .06 flat..............................1
82 00599 50005995 Roller unit, 2"....................................................1 104 54243 90542436 Spring, extension .75 x 3.50..............................2
83 00493 50004930 Shaft, 2" rear roller............................................1 105 54252 90542525 Clamp, loop-type...............................................1
84 38252 50382527 Roller, 1-1/2" IMC..............................................1 115 38592 50385925 Guide, spring.....................................................1
85 38253 50382535 Roller, 2" tail......................................................1 116 51130 90511301 O-ring, 1.50 x 1.62 x .062.................................2
86 38260 50382608 Shaft, 1-1/2" pivot roller....................................1 117 51537 90515374 O-ring, 1.75 x 1.87 x .062.................................2
87 32027 50320270 Sleeve, 1-1/2"...................................................1 118 38657 50386573 Shaft, 2 middle roller.........................................1
88 31728 50317288 Shaft, 2" pivot...................................................1 119 52644 90526449 Washer, 1/32 shim.............................................1
89 38151 50381512 Sleeve, 2"..........................................................1 150 52645 90526457 Washer, 1/16 shim.............................................1
90 23258 50232584 Grip...................................................................1 151 53216 90532163 Retaining ring #5100-62...................................1
854 Quad Bender
Drive Unit Exploded View and Parts List
22
15
13 22
14
16
12
8A 17
9
23 21
18
19
2 8 20
1 11
23 10
4
3 8
25
24 6
UPC No.
Key 78-3310- Part No. Description
5
1 1 86705 91867053 Commutator brushes
2 86706 91867061 Commutator brush retension springs
2 3 86707 91867070 Tail housing
4 86708 91867088 Brush assembly plate
5 86709 91867096 Cord
Bolt Tightening Sequence for Gearbox Cover 6 39092 50390929 Shroud
8 52028638 Armature/housing set
8A 86071 91860717 Bearing
1 9 54348 90543483 Belleville washers
6 10 39073 50390732 Rear gear housing
11 39074 50390740 Gasket
12 39075 50390759 Front gear housing
4 3
13 39076 50390767 Output gear shaft
14 39077 50390775 Short spacer
15 39078 50390783 Long spacer
2 5 16 39079 50390791 2nd Reduction pinion shaft w/ BRGs
17 53323 90533232 Wave washer
1. Torque gearbox bolts to 11/9 Nm (100/80 in-lb) in 18 39080 50390805 3rd Reduction pinion shaft w/ BRGs
sequence shown. 19 54248 90542487 Belleville washer
20 39081 50390813 4th Reduction pinion shaft
2. Assemble all Belleville washers so that I.D.’s butt
21 39082 50390821 Small spacer
and O.D.’s contact bearings.
22 54043 90540433 1/2-20 x 2-1/2 Screw
3. Tighten motor nuts (24) to 3/4 Nm (30/35 in-lb). 23 02298 50022989 1/4-28 x 9-1/4" Stud
4. Insert commutator brushes before connecting 24 51705 90517059 1/4-28 Hex nut
push-on terminals. 25 50749 90507495 1/4" Internal tooth lockwasher
854 Quad Bender
Main Exploded View

43
26 58
223 225
231
3
224 23
29 7
222 32
58
10
27 16
225
221 17 19 36 18
170
13 233
30
52 51 20
2 233
50 59
5 15
20A
60
22
23 8
Power Cord 37 14, 28

170
209, 211, 212 15
6
15 18 21
33 25 206
47 202
45
46 201
207
220 11
57 12
208
213
205
206
57D
57E 2
57A
57F
215
57C
57B 204
854 Quad Bender
95
118
89
73 82
231 98 105
54 117 85
83
71 104
104
84 95
72
115
80
79
18 15 81
79
80
203 117
76
88
93*
207 86
116
78
15
77 99, 119
100 or 150
77 93*
78
98
116
220 Note: These items *Torque to 94 Nm (70 ft-lb)
are available as 87 94
75
Part No. 50005740 93*
151
4, 28 Roller Support Unit. 101 90
9
176
106
44 107
29
228
226
92
31 227
11 96
12
6
21 91
224 74
97
4C
23 4B
26
4, 4A If the chain breaks, replace it with a new
226 chain — not another master link — due
to the high stress on the chain. The
229 addition of a second master link will only
weaken the chain further. If the master
link breaks, replace it with a new master
link (90542517).
854 Quad Bender
Main Parts List

UPC No. UPC No.
Key 78-3310- Part No. Description Qty. Key 78-3310- Part No. Description Qty.
2 01622 50016229 Frame weldment...............................................1 57 39839 50398393 Switch, pendant ...............................................1

3 38217 50382179 Guard weldment, top chain................................1 57A 86449 91864496 Switch, center off..............................................1
4 38983 50389831 Guard assembly, front chain..............................1 57B 31902 50319027 Handle, right half...............................................1
4A 38236 50382365 Guard, front.......................................................1 57C 53441 90534417 Screw, #6-20 x .625 pan head, self-tapping......3
4B 38244 50382446 Retainer............................................................1 57D 31901 50319019 Handle, left half.................................................1
4C 50160 90501608 Rivet, 3/16" pop................................................2 57E 39837 50398377 Cord..................................................................1
5 38232 50382322 Guard weldment, motor.....................................1 57F 35487 50354876 Decal, face plate................................................1
6 01607 50016075 Guard, bottom...................................................1 58 03129 50031295 Decal, angle......................................................2
7 38199 50381997 Support weldment, 1/2" to 1-1/4" RLR..............1 59 51751 90517512 Screw, drive......................................................4
8 38250 50382500 Drive unit...........................................................1 60 03101 50031015 Nameplate.........................................................1
9 01702 50017020 Spindle weldment, main....................................1 61 38892 50388924 Decal, warning (not shown)...............................1
10 38193 50381938 Plate weldment, drive........................................1 62 38893 50388932 Decal, lifting eye (not shown).............................1
11 54253 90542533 Sprocket, #60 14T.............................................1 65 03105 50031058 Decal, select switch size (not shown).................1
12 38267 50382675 Key, drive sprocket............................................1 67 38898 50388983 Decal, bender pivot lock (not shown).................1
13 54255 90542550 Bearing, sleeve #48DU40..................................2 68 38899 50388991 Decal, roller adjustment (not shown)..................1
14 54250 90542509 Chain, #60 92P..................................................1 69 02263 50022636 Decal, roller engagement (not shown)................1
15 54462 90544625 Ring, retaining Truarc #5100-200......................4 70 03100 50031007 Decal, operation (not shown).............................3
16 38265 50382659 Washer, main spindle.........................................2 71 38221 50382217 Support weldment, roller...................................1
17 38268 50382683 Key, shoe drive..................................................1 72 00528 50005286 Support weldment, 1-1/2".................................1
18 38457 50384570 Plate, hoist........................................................2 73 00601 50006010 Support weldment, 2".......................................1
19 55204 90552040 Pin, 1/2" to 1-1/4" support pivot.......................1 74 38225 50382250 Arm weldment, adjustment................................1
20 38257 50382578 Spacer, motor mount.........................................1 75 00543 50005430 Plate, 1-1/2" outer roller....................................1
20A 39488 50394886 Spacer, thin motor mount..................................1 76 00604 50006045 Plate, 2" outer roller..........................................1
21 38228 50382284 Locator eeldment, rccentric...............................1 77 38254 50382543 Rol, 1-1/2"........................................................2
22 54265 90542568 Nut, 1/2-13 lock................................................1 78 38264 50382640 Ball, 1-1/2".......................................................2
23 51655 90516559 Screw, #10-16 x .50 hex head.........................31 79 38255 50382551 Rol, 2"...............................................................2
25 53903 90539036 Screw, cap 1/2-13 x 1.00..................................4 80 38263 50382632 Ball, 2"..............................................................2
26 52501 90525019 Ring, retaining Truarc #5100-287......................2 81 38262 50382624 Spacer, 2" roller................................................1
27 54345 90543459 Screw, set 1/2-20 x .75 socket..........................1 82 00599 50005995 Roller unit, 2"....................................................1
28 54251 90542517 Link, connecting #60 chain................................1 83 00493 50004930 Shaft, 2" rear roller............................................1
29 52871 90528719 Screw, 1/4-20 x .75 socket...............................4 84 38252 50382527 Roller, 1-1/2" IMC..............................................1
30 03095 50030957 Pointer, 1/2" to 1-1/4".......................................1 85 38253 50382535 Roller, 2" tail......................................................2
31 03099 50030990 Pointer, 1-1/2" to 2"..........................................1 86 38260 50382608 Shaft, 1-1/2" pivot roller....................................1
32 03104 50031040 Spacer, pointer..................................................2 87 32027 50320270 Sleeve, 1-1/2"...................................................1
33 52597 90525973 Washer, flat .56 x 1.37 x .109............................4 88 31728 50317288 Shaft, 2" pivot...................................................1
36 86767 91867673 Strain relief, pendant ........................................1 89 38151 50381512 Sleeve, 2"..........................................................1
37 54124 90541243 Strain relief........................................................1 90 23258 50232584 Grip...................................................................1
43 38780 50387804 Shoe unit, 1/2" to 1-1/4"...................................1 91 38256 50382560 Shaft, eccentric.................................................1
44 38148 50381482 Shoe unit, 1-1/2" to 2"......................................1 92 38251 50382519 Sleeve, adapter.................................................1
45 52203 90522036 Screw, machine #6-32 x .25..............................2 93 50540 90505409 Screw, 7/16-14 x 1.00 hex head........................3
46 29708 50297082 Guard, breaker switch.......................................1 94 00860 50008609 Shaft, 1-1/2" support........................................1
47 86385 91863856 Breaker, circuit 20 amp.....................................1 95 54819 90548191 Retaining ring #5100-100.................................2
50 54927 90549279 Screw, cap #8-32 x 1.37 socket........................4 96 54242 90542428 Screw, cap 1/4-20 x .37 button head.................3
51 86841 91868416 Brake, motor.....................................................1 97 50224 90502248 Screw, 5/16-18 x 1.00 socket head...................1
52 38807 50388070 Key, brake.........................................................1 98 50881 90508815 Screw, 1/4-28 x .25 set.....................................2
54 54151 90541510 Knob, plastic w/ set screw.................................1 99 53018 90539184 Washer, 1.00 x 1.37 x .03 shim.........................1
854 Quad Bender
Main Parts List (cont’d)

UPC No. UPC No.
Key 78-3310- Part No. Description Qty. Key 78-3310- Part No. Description Qty.
100 54248 90542487 Washer, Belleville 1.362 x .803..........................2 212 38168 50381687 Knob.................................................................1
101 39440 50394401 Washer, .62 x 2.00 x .06 flat..............................1 213 38464 50384643 Pad weldment, jack bolt....................................4
104 54243 90542436 Spring, extension .75 x 3.50..............................2 215 54276 90542762 Caster, swivel....................................................2
105 54252 90542525 Clamp, loop-type...............................................1 220 38156 50381563 Block, reinforcement.........................................2
106 52108 90521080 Nut, hex 1/4-20.................................................1 221 31710 50317105 1/2" to 1-1/4" IMC, Rigid hook..........................1
107 54239 90542398 Screw, 1/4-20 x 3/4 ovl pt set...........................1 222 33494 50334948 1/2" to 1-1/4" Shoe..........................................1
115 38592 50385925 Guide, spring.....................................................1 223 31712 50317121 1/2" to 1-1/4" EMT hook...................................1
116 51130 90511301 O-ring, 1.50 x 1.62 x .062.................................2 224 52479 90524799 Drive bolt, 1/2-13 x .62
117 51537 90515374 O-ring, 1.75 x 1.87 x .062.................................2 socket head cap screw......................................6
118 38657 50386573 Shaft, 2 middle roller.........................................1 225 51088 90510887 1/2" to 1-1/4" hook bolts, 3/8-16 x 1-1/4
Socket head cap screw.....................................8
119 52644 90526449 Washer, 1/32 shim.............................................1
226 53396 90533968 1-1/2, 2" Hook shoulder bolts,
150 52645 90526457 Washer, 1/16 shim.............................................1 3/4 x 1-1/2 . .....................................................6
151 53216 90532163 Retaining ring....................................................1 227 38147 50381474 1-1/2, 2" Shoe..................................................1
170 86263 91862639 Nut, 1/2" conduit lock........................................1 228 31716 50317164 1-1/2, 2" EMT hook...........................................1
171 38974 50389742 Decal, circuit breaker (not shown).....................1 229 38779 50387790 1-1/2, 2" IMC and Rigid hook............................1
176 54911 90549112 Screw, 1/4-28 x 3/8" socket head cap..............2 231 01084 50030523 Selector switch unit w/o knobs..........................1
177 01453 50014536 Decal, shoe orientation (not shown)...................2 232 54880 90548809 Wrench, 5/16" hex T-handle .............................1
201 38141 50381415 Base weldment, trunion.....................................1
202 03135 50031350 Tower weldment, L.H. trunion............................1 Optional
203 03136 50031368 Tower weldment, R.H. trunion............................1 38962 50389629 Vinyl cover (not shown)
204 53390 90533909 Wheel................................................................2 01700 50017004 1/2" to 2" PVC shoe group
205 38166 50381660 Axle, long..........................................................1
Service Only
206 51528 90515285 Ring, retaining #5160-75...................................2
233 05586 500 5860 Frame unit (includes bearings)...........................1
207 54237 90542371 Screw, flange 3/8-16 x 1.00 hex......................16
208 52646 90526465 Nut, 3/8-16 Esna hex.........................................4
209 38167 50381679 Pin, trunion lock................................................1
211 54244 90542444 Spring, trunion lock...........................................1
121B 121M
Wiring Diagram
121P
121M
Greenlee / A Textron Company

121R
121Q 121P
Note: Use Loctite® #271 on

121S
all relay mounting screws.
120K 121Q 121R
120L 121R
120A 120M 124 121N 121I 121H 121G 121Q
121U
121K 121Q 121R
123 121K 121T
Serial Numbers ABT0000 through ABT1199
121Q
121R 121S 121A 121C
23
BLACK
34
120H
RED
120
WHITE 121
122
WHITE
TO BRAKE
-HV 126
120D BLACK BLACK
BLACK
RED +HV
YELLOW 121J
TO SELECTOR 120VAC WHITE
SWITCH UNIT GREEN
AC -HV 0VAC
(ITEM #127)
+HV AC
YELLOW
GREEN BLACK
WHITE
GREEN
120E 120G 120B 125 120F 120C GREEN

23 120I
120J 121E 121N 121L 121F 121F 121D 121C 121A
BLACK 121R
WHITE 121Q
TO DRIVE UNIT Note: Use heat transfer grease
between rectifier and PGU sub-plate.
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

854 Quad Bender
854 Quad Bender
Wiring Diagram Parts List

Key Part No. Description Qty. Key Part No. Description Qty.
120 50030507 I/O Assembly, basic 121G 50386395 Wire unit relay.......................................................1
(includes 120A-M and 121K)................................1 121H 50386409 Wire unit, PGU relay (rec)......................................1
120A 50030515 I/O Board, basic....................................................1 121I 50381750 Wire unit, PGU power (black)...............................1
120B 50386476 Transformer unit....................................................1 121J 91866448 Support, circuit board...........................................4
120C 90527658 Screw, #10-16 x 1/2" pan head............................2 121K 91866456 Contactor..............................................................2
120D 50017047 Sub-plate, I/O.......................................................1 121L 91859972 Rectifier, 600V 35A I-P..........................................1
120E 91866448 Support, circuit board...........................................6 121M 90543300 Screw, machine #6-32 x .50 Phillips head............2
120F 91867720 Resistor unit, motor shunt....................................1 121N 90543319 Screw, machine #6-32 x .75 Phillips head............3
120G 90540417 Nut, hex #4-40......................................................1 121P 90543327 Screw, machine #6-32 x 1.00 Phillips head..........2
120H 50386395 Wire unit, relay......................................................1 121Q 90506324 Nut, hex #6-32......................................................7
120I 90549260 Screw, #4-40 x .375..............................................1 121R 90523245 Washer, lock, .145 x .236 x .025...........................7
120J 90537238 Washer, lock.........................................................1 121S 91866766 Insulator, heat transfer..........................................2
120K 90543319 Screw, machine #6-32 x .75 Phillips head............2 121T 50389602 Wire unit, PGU power #6 stud..............................1
120L 90506324 Nut, hex #6-32......................................................2 121U 50389610 Wire unit, PGU relay #6 stud................................1
120M 90523245 Washer, lock .145 x .236 x .025............................2 122 50389416 Wire unit, PGU to breaker.....................................1
121 50389025 Power generation unit (includes 121A-U).............1 123 91868394 Wire unit, I/O to PGU............................................1
121A 50382713 Sub-plate, PGU....................................................1 124 50386484 Wire unit, I/O to PGU............................................1
121B 50382705 Heat sink, PGU.....................................................1 125 50017411 Wire unit, I/O to power..........................................1
121C 50383132 Board, power generation......................................1 126 50386034 Cord unit, power...................................................1
121D 50386417 Wire unit, rectificer (black)....................................1 127 50030523 Switch unit, selector.............................................1
121E 50386425 Wire unit, rectificer (rec)........................................1 128 90542797 Tie, cable (not shown)...........................................3
121F 50386433 Wire unit, rectificer (yellow)...................................2
854 Quad Bender
Basic I/O Electrical Schematic (50030515)

Serial Numbers ABT0000 1N5400
through ABT1199 D103
RELAY COM
RELAY NO
J103
White
Red
+
2
C
1
C
1N5400
1N5400
JP101
GND
ELEC.
BRAKE
BRAKE SW.
D102
D101
4700uF/25V
C101
4700uF/25V 1N5400 J101
3
D2
C4
4
1N5400
120 VAC IN
1
GND
12V
6
D1
VI
TRANSFORMER
J102
U3
G
MFJ6M
2
VO
3
100uF/16V
+12V
C3
1
VI
U4
G
2
VO
5V
22uF/16V
C2
+5V
POWER R5 R2
220
+5V
Green
2.2M 470K
GND
R15
B
D3
Q1
1K R6
E
R9 2.2M
GND
2N3906
1K
.1u/50V
R10
C11
4.7K
R1
DIR A 1K
220
Red
D4
R17 R11
10k
R20
.1u/50V
9
8
7
6
5
4
3
2
1
PIC16C620
BEND
J3
RB3
RB2
RB1
RB0
VSS
MC LR
RTCC
RA3
RA2
C10
4
3
TO DIR SWITCH
Red
10k
U2
10K
Black
R24
White
R21
OSC2
OSC1
VDD
RB4
RB5
RB6
RB7
RA0
RA1
2
1
UNLOAD
DIR B
220
+5V
Amber
10
11
12
13
14
15
16
17
18
D5
R16
R3
4.0Mhz
22K 1K
X1
2.2K
R23
10K
R18 R13
B
Q4
10K
R22
+5V
3.3K 1.8K
+12V
GND
10K
R7
E
2N3904 R14 R12

B
Q3
1N4007
GND
R19
D6
1K
2N3906
B
Q2
Jumper Wire Across Pins 2 & 3

3
2
1
220 220
2N3904
+5V
B
JP1
R8
R4
2N3904
Q5
1N4007
E
D7 .1u/50V
GND .1u/50V
GND
C8
C5
GND
.1u/50V
1
3
TO PGU
C9
J2
TO RELAY COIL
4
6
5
+12V
2
1
J4
854 Quad Bender
Basic I/O Electrical Schematic (50030515) Parts List

Reference Part Number Description Manufacturer
D6,D7 1N4007 Diode

D1,D2,D101,D102,D103 1N5400 Diode
Q2,Q4,Q5 2N3904 Transistor
Q1,Q3 2N3906 Transistor
C5,C6,C7,C8,C9,C10,C11 .1U/50V Filter Capacitor
P1 3-pin Male IDC Connector
D3 5 mm Round Green LED
D4 5 mm Round Red LED
D5 5 mm Round Amber LED
U4 MC7805 TO-220 5 VOLT Regulator
U3 MC7812 TO-220 12 VOLT Regulator
J4,J103 39-28-1023 Connector 2-pin Minifit Jr. Molex
U2 918 6869.6 Processor, Programmed 555/854 Greenlee Textron
C2 22U/16V Electrolytic Capacitor
C3 100U/16V Electrolytic Capacitor
C4,C101 4700U/25V Electrolytic Capacitor
R9,R10,R11,R13,R19 1K Resistor
R12 1.8K Resistor
R14 3.3K Resistor
R4,R8,R15,R16,R17 220 Resistor
R18 22K Resistor
R2 470K Resistor
R7,R20,R21 10K Resistor
R3 2.2K Resistor
R5,R6 2.2M Resistor
R22,R23,R24 10K Resistor
X1 4MHZ Ceramic Resonator
U2 18-pin .3 DIP Socket
854 Quad Bender
PCB Layout (50030515)

TO PGU TRANSFORMER 120 VAC

RED WHITE 6 5 4 6 5 4 4 3
3 2 2 1 3 2 2 1 2 1
U3 +
D6 + C3
R12
D1
Q3
D2
D102
D101
R14
C101
R18 Q4 R13
+
R4
R8 Q2 C2
+
U4
+ C4 Q1
C1
R7
R3
C6 U2 R5 R2
R1
R6
C7 PGM
C8 C9
PWR
R15
D3
U1
R9 C5 X1
DIR B
R17
D4
R21
R10
DIR A
R16
D5
R20
R11 C10
C11
R19
Q5
D103
1 1 2 12V
1
D7
5V
2
2 GREENLEE TEXTRON 3 4
GND
RELAY 500 3051.5 REV. 1 BRAKE DIR. SWITCH
through ABT1199
Molex
MFJ

Serial Numbers ABT0000
J3:2
DIRECTION 2
1
CONTROL VCC
J3:1 1N4007
K A
D7 C1
K1 1
6 U1:A 1u/50V
J2 3 2
5
4 direction relay
3 4049
2 U1:E MOTOR +
1 11 12 +HV INPUT(RED) OUTPUT
J7:1 TO MOTOR +
Molex 4049 1 C2 J5:1
1 RED(+) C1 1
Mini-fit Jr. U1:C
R1 7 6 C3
VCC J4:1 J7:2
4.7K 4049 2 C5 J5:2
R2 D1
C4 2
4.7K U1:D SKR2F17 2 BLACK(-) MOTOR - C6
U1:B R3 9 10 INPUT(BLK)
5 4 L2 OUTPUT
4049 J4:2 J6:1 TO MOTOR -
4049 10K Q2 1 L1
T1 R4 IXFH40N30 DIRECTION
R5 R6 U2 8 14 U1:F 15 2
2 6 2N3904 CONTROL
10K 10K 4049 22 J6:2 K2
3 5 8 Mini-fit Jr.
HP4502 VCC R7
39
8 7 D2
2 - 68K
U3:A 8 R8
1 2 -
U4:A 10K
Power Generation Unit Schematic Diagram
1N4744
3 LM393NE 1
+
R10 4 3 5 R9
+ LM393NE U4:B +
680 R11 .04/5W
4 7
D3 10K
- 6
1N914 LM393NE
R12 R13 C2
VCC 1u/50V
10K 330
R21 VCC
120vac 680
L1
J1:1 +HV
1
120 VAC
HURRICANE HL8196 D4
R14
1N914
4.7K/10W
R18
R19
R15 R16 20K/2W K
C3
D6
10uF/250VAC
R17
C4
1N4744
L2 C5 DS1 A
330u/25V
J1:2
2 GRN
NEUTRAL
1000u/250V
HURRICANE HL8196
0vac
R20
J1:3
3 Notes: -HV
GROUND • Relay K2 mounted off-board.
• Bridge rectifier mounted off-board.
• Varistors are V150LA20A.
• All resistors 1/4W unless noted.

854 Quad Bender
854 Quad Bender
Power Generation Unit Parts List

Greenlee No. Location Description Value Manufacturer Part No.

— R1,R2 Resistor 4.7 KΩ / 1/4 w / 5% — —
— R3,R5,R6,R8, Resistor 10 KΩ / 1/4 w / 5% — —
R11,R12
— R4 Resistor 22 Ω / 1/4 w / 5% — —
— R7 Resistor 68 KΩ / 1/4 w / 5% — —
— R9 Resistor .04 Ω / 5 w / 1% Dale LVR-5 .04Ω
— R13 Resistor 330 Ω / 1/4 w / 5% — —
— R14 Resistor 4.7 KΩ / 10 w / 5% Dale CW-10 4.7K
— R10,21 Resistor 680 Ω / 1/4 w / 5% — —
— R15–R18,R20 Varistor V15 0 LA 20A GE V150 LA20A
— R19 Resistor 20kΩ / 2w / 1% Dale RS-2B-20K
91866871 D1 Diode — Semikron SKR2F17
— D2,D6 Zener Diode IN4744-DO-41 Motorola IN 4744
— D3,D4 Diode IN914 Motorola IN 914
— D7 Diode IN 4007 Motorola IN 4007
— C1,C2 Capacitor 1mf / 50v Philips CY-30 C105M
— C3 Capacitor 10mf / 250 VAC American 10mf / 20VAC
— C4 Capacitor 330mf / 25v Nichicon 1E331MPA
91868629 C5 Capacitor 1000mf / 250v Nichicon LLR2D
91866880 K1 Relay T81H5D312-05 P & B T81H5D312-05
91866456 Off Board Relay PRD-11DYO-12 P & B PRD-11DYU-12
— L1,L2 Inductor HL-8196 Hurricane HL-8196
— DSI LED LED T1-3/4 Green HP HLMP-3507
91866901 U1 IC 4049 Motorola MC14049UBCP
91866910 U2 Opto-Isolator 6N136N HP HCP4502
91866928 U3,U4 IC LM393 Motorola LM393AN
91859972 Off Board Bridge Rectifier GBPC3504 GI GBPC3504
91868610 Q2 Mosfet IXFH40N30 IXYS IXFH40N30
— D1 Heat Sink — Wakefield 695-1
50382705 Off Board Heat Sink — Greenlee —
— J1 Connector — Beau 72503
— J2 Connector Mini-Fit Jr. Molex 39-28-1063-P
— J3,J7 Connector Mini-Fit Jr. Molex 39-28-1023-P
— J4 Connector — Beau 72502
— J5,J6 Connector Mini-Fit Jr. Molex 39-01-2020-P
91866936 T1 Transistor 2N3904 Motorola 2N3904
854 Quad Bender
Power Generation Unit Layout Diagram

R21 U3 U2 TO I/O J1 LINE NEUTRAL GND
R10
1 12
R6
R5
6 5 4
2 11
D3
R13 1 2 3
+ J2
R12 K1
TO RELAY 7
R1 U1 C1
U4 J3 R15 R20
R8 1
D7
R3
R4
R2
D4 D6
T1
R16
R7
C4
+
L1 L2
D2
C2
+
R11
R9
R14
D1
Q2
C3
ANODE R18
GREENLEE
TEXTRON R19
500 3646.7 R17
+
C5
DS1
J4
BLK (-) RED (+) -HV +HV 120VAC 0VAC
Wiring Diagram

120 120B 120C
121
23
TO RELAY
BLACK BLACK RED
TO I/O
RED
CN2
122 47 126
42
WHITE
CN1 WHITE
RED
RED
BLACK BLACK BLACK
BLACK
FROM RECTIFIER
BLACK
TO BRAKE
YELLOW WHITE WHITE
(ITEM #51)
JP1
GREEN
TO SELECTOR AC -HV
YELLOW YELLOW
SWITCH UNIT
+HV AC
(ITEM #127)
YELLOW
120A GREEN
123
WHITE
BLACK
GREEN
TO DRIVE UNIT
120D

854 Quad Bender
854 Quad Bender
Wiring Diagram Parts List

Key Part No. Description Qty.
120 50060180 854 I/O Control Assembly....................................1

120A 50060376 Wire Unit, Power — DC........................................1
120B 50060368 Wire Unit, Power — AC........................................1
120C 50386484 Wire Unit, I/O — PGU...........................................1
120D 50060406 Wire Unit, Ground.................................................1
121 50054678 PGU2 Assembly...................................................1
122 50389416 Wire Unit, PGU to Breaker....................................1
123 91868394 Wire Unit, I/O to PGU...........................................1
126 50386034 Cord Unit, Power..................................................1
127 50030523 Switch, PCB Direction..........................................1
128 90542797 Tie, Cable (not shown)..........................................3
X1
4.0 MHz
1 +5V +12V
2 JP1
1
3
2
3
4
5
Molex 26-60-4050
DC POWER IN
R1 R2 R3 R4 R6 +12V
10K 10K 10K 10K 330
JP2
+5V +5V D2 D1 1
GREEN LED UF1001DI 2
POWER
I/O Electrical Schematic (50060180)
Molex 39-28-1023
MECHANICAL BRAKE
U1
15 R7
OSC2/CLKOUT
D3 R8 10K R5
1N4148 10K 17 470 Q1
RA0/AN0
44
18 TIP122
RA1/AN1
1
RA2/AN2/VREF
R9 2
RA3/AN3
1K 3
RA4/TOCKI
4
MCLR 6 UNUSED1
16 RB0/INT
OSC1/CLKIN 7 UNUSED2
RB1
8 DIR B
RB2
9 DIR A
RB3
C1 10 MECH BRAKE
RB4
.1uF/50V 11 RUN/BRAKE +5V
RB5
C2 12 DIRECTION
RB6
4.7uF/50V 13 PWM
RB7
+5V +12V +12V
PIC16C620
JP3 R22 R10 R23
1
10K 150 10K
2
R11 R12 R13 D4 R14 D5 Molex 39-28-1023 JP4
470 150 470 UF-1001-DI 470 UF-1001-DI RELAY COIL 1 2
3 4
_DIRECTION_ _RUN/BRAKE_ Molex 39-28-1043
R15 R16 D6 PENDANT D7
Q2 10K 10K RED LED AMBER LED
PN2222A Q3 Q4 DIR A DIR B
PN2222A PN2222A R17 R18
10K C3 10K C4
_PWM_ .1uF/50V .1uF/50V
R19 R20 R21

1K 330 330
+12V
JP5
1 2 Note: All resistors 5% 1/4W unless noted.
3 4
5 6
Molex 39-28-1063
TO PGU

854 Quad Bender
854 Quad Bender
I/O Electrical Schematic (50060180) Parts List

Reference Supplier Part Number Description Qty.

C1,C3,C4 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 3
AVX SA115C104KAA
KEMET C420C104K5R5CA
C2 Panasonic ECE-A50Z4R7 Capacitor, 4.7 uF, 50 volts 1
D1,D4,D5 Diodes Inc. UF-1001-DI Diode, Ultra-Fast Switching Rectifier 3
D2 Panasonic LN38GP LED, T1, Green 1
Liteon LTL-4231
D3 Generic 1N4148 Diode 1
D6 Panasonic LN28RP LED, T1, Red 1
Liteon LTL-4221
D7 Panasonic LN48YP LED, T1, Amber 1
Liteon 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 1
Generic #4-40 Lock Washer Stainless Steel, Split Ring or Internal Tooth 1
Generic #4-40 Hex Nut Stainless Steel 1
Generic #4-40 Phillips Screw Stainless Steel, Machine, Pan Head, #4-40 x 0.25" 1
Q2,Q3,Q4 Generic PN2222A Transistor, NPN 3
R1,R2,R3,R4,R7,R8,R15, Generic Resistor, 10K, 1/4 watt, 5% 12
R16,R17,R18,R22,R23
R5,R11,R13,R14 Generic Resistor, 470 Ω, 1/4 watt, 5% 4
R6,R20,R21 Generic Resistor, 330 Ω, 1/4 watt, 5% 3
R9,R19 Generic Resistor, 1 kΩ, 1/4 watt, 5% 2
R10,R12 Generic Resistor, 150 Ω, 1/4 watt, 5% 2
U1 Greenlee 91869382 Processor, Programmed, 854 1
X1 Murata CST4.00MGW Resonator, 4.0 Mhz 1
Panasonic EFO-GC4004A4
854 Quad Bender
PCB Layout (50060180)

GREENLEE TEXTRON ©2000

R10
C1
C3 JP4
Q4 R22
SELECTOR
R5 R17
4
R14 R18
R13 R23 R15
R11 R16
3
R8 DIR B
R9 C4 D7
JP1
X1 R7
Q3
R4 R21
R1 R3 DIR A
R2 U1 D6
D4 R20
D3
C2
+
Q2 POWER
D2
1
JP5
4
R6
5
R12 BRAKE RELAY

3
6
1
JP2 JP3
Q1
2
TO PGU
2
R19
D1
D5
Mounting Hardware for Q1 and D8
Heatsink:
+15 V Thermalloy Inc.
D1 R1 THM7023B-MT
Insulator:
2K Power Devices, Inc
YELLOW LED KA-118-094
DIRECTION R3
1M C1 C13 C2 #4-40 Flat Washer (x2)

D2 R2 .1uF/50V .1uF/50V 1uF/63V #4-40 Lock Washer:
1M R4 R5 R7 R6 #4-40 Nut
150K 12K/1% 20K/1% 4.75K/1%
RED LED R10 #4-40 Phillips Screw
3
PWM U1B 100K
5 LM339 R9 Tighten Q1 and D8 to 5 in-lb
1
8
J1 + 2 22 D5
4 6 D8 should mount to lower hole
1 2 - 2 in heat sink.
3
3 4 U1A 7 1N4148
5 6 R13 D6 7 LM339 R11 Q1 should mount to upper hole
12
Molex 39-28-1063 100K 1N4148 + 1 U2 22 in heat sink.
4
5
R12 6 MIC4422BN
TEST CONNECTOR 1M S1 - Do not trim insulator.
D4 R8 R26
D7
R14 R16 1.5K/1%
12
1M 1N4148 EVQ-PAC09K 10K/1%
GREEN LED 2K +170 V
VCC
C3
.01uF/50V 1 J10
J2 U3 +15 V RED
2 8 D8 2
1 2
DSEI30-06A TO RELAY (Contacts 6 and 7)
3 4 7
5 6
Molex 39-28-1063 3 6 R24 1 J11
TO I/O 5 20K/1% BLACK
HCPL4502 2
3
U1D TO RELAY (Contacts 5 and 8)
11 LM339 Q1
+ 13 IXFK73N30
47
10
R19 D9 -
UF1001DI +15 V
1K R25 D3
12
J4 10K/1% 1N5245B
2
1 R27
27.4K/1% R22
Q2 Molex 39-28-1023 U1C 100/1%
3
PN2222A TO RELAY COIL (Contacts 1 and 2) LM339

9
R21 14 +
1K 8 R23
D13 - 10K/1% R15
R28 C12 .040/5W/1%
1.5K/1% .1uF/50V
12
1N4007 +15 V
R17
D14 4.7K/10W
Power Generation Unit Schematic Diagram (50054678)
1N4007 +170 V
J5 J6
1 1
2 2
J7 YELLOW RED R18
C5 AC DC+ 20K/2W/1%
3 LINE .0047uF/500VAC C4
NEUTRAL R20 .010uF/500VAC D10
2 1.5M TO BRIDGE 1N5245B
GROUND
1 L1 C11 RECTIFIER C6
Beau 72503-C 470uH .010uF/500VAC D11 1000uF/250V C7
AC POWER IN C8 GREEN LED 680uF/25V
.0047uF/500VAC POWER
J8 J9
1 1
2 2
YELLOW BLACK +15 V
AC DC-
Notes:
• Bend leads on R17 to mount at least 0.25" off-board.
• All resistors 5% 1/4W unless noted. C9 C10
.1uF/50V .1uF/50V

854 Quad Bender
854 Quad Bender
Power Generation Unit Parts List (50054678)


C1,C9,C10,C12,C13 Philips A104K29X7RFVVWN Capacitor, 0.1 uF, 50 volts 5
AVX SA115C104KAA
KEMET C420C104K5R5CA
C2 WIMA MKS21.06310 Capacitor, Film, 1 uF, 63 volts 1
C3 Philips A103M15Z5UFVVWA Capacitor, .01 uF, 50 volts 1
AVX 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 1
Cornell Dubilier 380LX102M250K052
C7 Panasonic EEU-FC1E681 Capacitor, 680 uF, 25 volts 1
D1 Panasonic LN48YP LED, T1, Amber 1
Liteon LTL-4251
D2 Panasonic LN28RP LED, T1, Red 1
Liteon LTL-4221
D3,D10 Motorola 1N5245B Zener Diode, 15 volts, 500 milliwatts 2
D4,D11 Panasonic LN38GP LED, T1, Green 2
Liteon 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) 1
Adv Pwr Tech APT30D40B
Adv 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 1
L1 Renco RL-1328-22-470 Choke, Common Mode 1
Q1 IXYS IXFK73N30 MOSFET, N channel, 73-76A, 300V, TO-264 (see Note 2) 1
Adv 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% 1
KRL NP-5A .04W
Riedon 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) 1
KRL C-10A 4.7K
Riedon UT-10 4.7K
R18 Dale RS-2B-20K Resistor, 20 kΩ, 2 watt, 1% 1
KRL C-2A 20K
Riedon UT-2B 20K
854 Quad Bender
Power Generation Unit Parts List (50054678) (cont’d)


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 1
QT-Opto HCPL4502
Siemens 6N136
Note 1: Mount D8 to bottom hole of heat sink.
Note 2: Mount Q1 to top hole of heat sink.
Note 3: Bend leads and mount .25" off-board .
Layout Diagram — Power Generation Unit (50054678)

TO I/O Line Neutral Ground
Q2
R8
6 5 4
3
6
J2
PWM
DIR
VCC
D2
3 2 1
TEST
D1
D4
R21
R19
4
1
J7
R1
1
2
U3
J4
+
D9
C5
C8
C7
C10
R20
D10
R10
R12
R16
R26
R2
R5
R6
R3
R4
R7
C1 C2
S1
U2
C3
C9
C13
D6
U1
R13
R14
D7
R24
R27
R28
R23
R22
R11
R25
R9
C12
D5
R17
L1
C11
D13
D14
+
J10
C4
Red
TO RELAY
POWER
D11
D8 Black
J8
J5
D3
J11
R15
Yellow Yellow
Q1
C6
R18
GREENLEE TEXTRON
Red Black ©2000
J6
J9
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INSTRUCTION MANUAL

Read and understand all of the instructions and

99922223 © 2007 Greenlee Textron Inc. IM 1301 REV 13 10/07

Table of Contents Safety

KEEP THIS MANUAL

IMPORTANT SAFETY INFORMATION

Hazards which, if not avoided, COULD result in

Read and understand all of the

Do not use this tool in a hazard-

IMPORTANT SAFETY INFORMATION

Unplug the bender before changing accessories.

Do not operate the bender while wearing loose

854 Conduit Bender

1. Bender Power Head 9. Support Roller Squeeze Adjustment

Transportation and Setup

The bender head has two bending positions — vertical

Using the 1-1/2" to 2" Roller Support Unit

Due to variations in conduit, the standard adjustment

Illustrated Bending Glossary

back-to-back bend — any U-shaped bend formed by two

center-to-center distance — the distance between the suc-

developed length — the actual length of pipe that will be bent;

gain — the difference between the straight-line distance

a 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

offset bend — two opposite bends with the same degree of

offset height — the distance between the two legs of

rise — the distance from the end of a straight section of

saddle — a three-bend or four-bend combination; used

shrink — the amount of conduit “lost” when laying out an

springback — the amount, measured in degrees, that a

Deduct Table BENDING DEDUCT

Scale Reading Table

Bending Instructions (cont’d)

X Table Offset Table

Special Bending Information

1. Select the size and type of conduit. Determine the

Offsets — Working Past an Obstruction

Special Bending Information (cont’d)

BENDING BENDING BENDING

Special Bending Information Chart

Special Bending Information Chart (cont’d)

Y 30 1.72 5.72 9.72 13.72 17.72 23.72 29.72 41.72 65.72

Special Bending Information Chart (cont’d)

Special Bending Information Chart (cont’d)

Special Bending Information Chart (cont’d)

Special Bending Information Chart (cont’d)

Roller Supports Cleaning and Every 6 months*

Drive lugs closest

5. Mount the replacement shoe onto the spindle. Align

Problem Probable Cause Probable Remedy

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

Check that switch is ON.

Unusual conduit characteristics. Adjust pointer or bend to a smaller

Too little squeeze on 1-1/2" or 2" Increase squeeze per adjustment

Unusual conduit characteristics. Adjust pointer or bend to a larger

Is the current on the 115 VAC line NO

Won’t bend Won’t stop