Gardner Bender B2000 Cyclone Troubleshooting Manual
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Gardner Bender B2000 Cyclone Troubleshooting Manual

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GAR_TL_045_0717
SERVICE INSTRUCTIONS
These Service instructions are intended for use by a qualified personal at Authorized Gardner Bender Service
Centers. Users of Gardner Bender equipment should see the bender instruction sheet for installation, operation and
maintenance information.
SAFETY ISSUES
WARNING
is reserved for conditions and actions that can cause serious or fatal injury.
CAUTION
is reserved for conditions and actions that can cause injury or instrument damage.
WARNING:
• Do not locate the bender on damp or wet surfaces. Do not stand on damp or wet surfaces when repairing
or operating the bender.
• To avoid electrical shock, always unplug the bender power cord before removing end plates, motor or any electrical wiring.
CAUTION:
• To avoid physical injury, use two people to remove and install the bending shoe or to move it from place to place.
• Keep hands, clothing and electrical power cords away from moving rollers, bending shoe and exposed gears.
• Prior to installation: apply a coat of molycoat or equivalent to all shafts. When installing shafts,
use soft head mallets to seat in position.
REQUIRE TOOLS AND TEST EQUIPMENT
•
Torque Wrench
•
Allen Wrench
•
Open Wrench ½" and 9/16"
•
Sockets
•
Lithium Grease
•
Soft Head Mallet

TABLE OF CONTENTS

1.0 Troubleshooting Guide .........................................2-6
2.0 Pendant Troubleshooting ........................................ 6
3.0 Disassemble Instructions ....................................... 7
Limit Switch ..................................................... 7
Roller Housing ................................................. 7
Bender Shoe .................................................... 7
Circuit Board .................................................... 7
Electric Motor .................................................. 7
Drive Sprocket Assembly ................................ 8
4.0 Reassembly Instructions ........................................ 8
Drive Belt and Sprockets ................................ 8
Motor Assembly .............................................. 9
Shoe Shaft ....................................................... 9
Roller Housing ................................................. 9
Prinited Circuit Board ...................................... 9
Limit Switch Assem/Wiring ............................. 9
Troubleshooting Guide
B2000 Cyclone
•
2" EMT and Rigid Conduit
•
Silicone sealant
•
Multimeter
•
Strap Wrench
•
Repair Parts Sheet
•
Instructions Manual
5.0 Zero Adjustment .................................................... 10
6.0 Parts Breakdown ................................................... 11
B2000 Bender ................................................ 11
Bottom of Electric Motor .............................. 12
Shoe ............................................................... 13
Limit Switch ................................................... 14
Roller Housing ............................................... 15
Upper Roller / Handle ................................... 16
Sprocket Housing .......................................... 17
Handle / Control Circuit ................................ 18
7.0 Wiring Schematic .................................................. 19
8.0 Limit Switch Wiring Diagram ................................ 20
9.0 Maintenance .......................................................... 21
1
Bender
®

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  • Page 1: Table Of Contents

    ® GAR_TL_045_0717 SERVICE INSTRUCTIONS These Service instructions are intended for use by a qualified personal at Authorized Gardner Bender Service Centers. Users of Gardner Bender equipment should see the bender instruction sheet for installation, operation and maintenance information. SAFETY ISSUES WARNING is reserved for conditions and actions that can cause serious or fatal injury.

  • Page 2: Troubleshooting Guide

    1.0 TROUBLESHOTTING GUIDE *Note: Troubleshooting or maintenance that requires the B2000 to be disassembled in any way should be done by a professional indicated by Gardner Bender to avoid permanent damage to the machine. Contact nearest Gardner Bender Service Center for guidance.
  • Page 3 Drive belt tensioning Belt is worn out. Belt may be worn or damaged and must be replaced, seems loose. Part Number – CL310014. Refer to “Drive Sprocket Assembly” in “DISASSEMBLY” section (page 8) for instructions. Tensioner failure. Tensioner may be damaged and must be replaced, Part Number – CL306900. The motor must be removed in order to remove the tensioner.
  • Page 4 Bender shoe will not Jog button Unplug bender power cord. Perform continuity check on wire harness. return when pressing malfunctioning. Attach leads to red and green wires, Depress override (jog) button. return and jog button. *The colors described here are not present on the model B2000-7 and B2000-8 pendant harness (B2000 SERIAL NUMBERS BEGINNING WITH LETTERS “J”...
  • Page 5 Bender consistently Braking resistor on P.C. Unplug bender power cord. Perform resistance measurements on braking develops over bends board is malfunctioning. resistor. Remove chassis from rear of bender. Attach ohm meter across to brown and gray wires. If meter reads above 11 ohms, replace resistor. Refer to “Circuit Board”...

  • Page 6: Pendant Troubleshooting

    Bend function works, Direction circuit on P.C. Replace P.C. board. return function results board is malfunctioning. Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions. in bending direction. Return function works, Brake circuit on P.C. If all other tests are positive, replace P.C. board. bend function results in board is malfunctioning.

  • Page 7: Disassemble Instructions

    3.0 DISASSEMBLY INSTRUCTIONS Bender Shoe (Figure 1 & 2) 1. Prior to removing the bending shoe, the limit switch assembly must be removed. Refer to “LIMIT SWITCH” IMPORTANT: To avoid unnecessary service, the bender in the disassembly procedures. should be tested prior to any service work. Please refer to the maintenance section in the instructions manual and 2.

  • Page 8: Drive Sprocket Assembly

    elbow and pull the wires out. 4.0 RE-ASSEMBLY INSTRUCTIONS 6. Remove the rear access plate by removing 4 cap screws and washers. Drive Belt And Sprockets (Figure 6) 7. Remove the four cap screws and washers (Figure 6 1. Position drive belt sprocket (Figure 6 Item #24) and Item #18 &...

  • Page 9: Motor Assembly

    Motor Assembly (Figure 6 / Insert A) 3. Place shim (Figure 1 Item #22) and washers (Figure 1 #21) over the shaft. Install the complete roller housing 1. Remove restraint from drive belt. on the shaft. Secure with cap screw (Figure 5 Item 2.

  • Page 10: Zero Adjustment

    5.0 ZERO SET ADJUSTMENT TO ENSURE ACCURATE BENDS, THE BENDER ZERO ADJUSTMENT MUST BE ACCOMPLISHED AFTER RE-ASSEMBLY. 1. Plugs bend power cord into 110/115V outlet. Push upper roller assembly against the stop on the sprocket housing (Figure 19). 2. Press and hold “ADVANCE” on pendant switch until RIGID side of shoe is facing the upper roller housing. 3.

  • Page 11: Parts Breakdown

    Figure 1 Figure 1 B2000 Bender Assembly B2000 Bender Assembly (See Fig. 7) SEE INSERT A Page 3 & Fig. 6, (page 8)

  • Page 12: Bottom Of Electric Motor

    INSERT A B2000 Bender Assembly, cont. B2000 Bender Assembly Item # Part # # Req’d Description Item # Part # # Req’d Description CU295900K Roller Housing Assm (Figure 4) Figure 2, pg. 4 Shoe Sub Assm CK696108 Washer Figure 3, pg. 5 Limit Switch Assm CL229248 Shim...

  • Page 13: Shoe

    Figure 2 Shoe Subassembly Shoe Subassembly Item # Part # # Req’d Description CL199809K Shoe Bending (Incl. items 7, 8, 9 and 10) Shoe Subassembly, cont. CN542005 Clamp, IMC (Incl. items 4, 5, 6) Item # Part # # Req’d Description CN541005 Clamp, EMT (Incl.

  • Page 14: Limit Switch

    Figure 3 Limit Switch Assembly B2000CK Clamp kit Limit Switch Assembly CM802950N Knob Sub Assembly Kit Item # Part # Description B2000HCK Clamp Kit CM767108 Washer ZCM793055N Thread Locker (for #1) not pictured CM801950 Upper Plate Assembly CM802950N Knob Sub Assembly Kit B2000-TRK CM767108 Trip Ring Assembly Kit...

  • Page 15: Roller Housing

    Figure 4 Roller Housing Assembly – CU295900K NOTE: Item 11 is a separate assembly not included with the roller housing (Figure 5). Roller Housing Assembly-CU295900, cont. Item # Part # # Req’d Description CU300281 ⁄ " Roller (Set of 2) CU297104 Shaft, Roller Roller Housing Assembly-CU295900K...

  • Page 16: Upper Roller / Handle

    Figure 5 Upper Roller and Handle Assembly – CK994900 Upper Roller and Handle Assembly-CK994900 Item # Part # # Req’d Description Common Repl. 1" External Retaining Ring Part CK569108 Washer CK575281K ⁄ "-1" Roller CK295107 Bearing (Set of 2) CL30900 Roller Axle Assembly Common Repl.

  • Page 17: Sprocket Housing

    Figure 6 Sprocket Housing Assembly - DA7058900 Sprocket Housing Assembly - DA7058900 Sprocket Housing Assembly - DA7058900, cont. Item # Part # # Req’d Description Item # Part # # Req’d Description CL310014 Drive Belt CL53107 Bearing CL306900 Includes: CL12108 Washer Tensioner Assembly Common Repl.

  • Page 18: Handle / Control Circuit

    Figure 7 Handle and Control Circuit Assembly – HC12 7, 8 3, 4 HC12 Contents Item # Part # # Req’d Description CJ458885 Locknut CM178647SR Plug Assembly CM32006 Receptacle, Power Cord CM25061 Pin, Cord Receptacle PO5C Pendant Station Assm Common Repl. #6 -32 X ⁄...

  • Page 19: Wiring Schematic

    Wiring Schematic ZERO STOP SWITCH BEND LIMIT SWITCH RETURN LIMIT SWITCH Typical Switch Contacts BLACK GREEN WHITE COMMON (OPEN) (OPEN) NORMALLY OPEN BLOCK MOUNTING BLUE NORMALLY CLOSED ORANGE (OPEN) NOTE: 2-LONG STUDS FOR COVER MOUNTING ONLY BOTTOM OF MOTOR WHITE ORANGE GREEN (42)

  • Page 20: Limit Switch Wiring Diagram

    Limit Switch Wiring Diagram: Rear view Front view (insert terminals) (face connects to PC board) Yellow Grey Grey Yellow Black Blue Blue Black White Orange Green Green Orange White Yellow – from motor Grey – from motor Red – from zero stop switch Black –...

  • Page 21: 9.0 Maintenance

    9.0 MAINTENANCE A troubleshooting aid exists on the printed circuit board mounted to the inside of the operating handle. If all systems are functional, a white L.E.D. (pictured in Figure 13) will flash once every two seconds while the machine is powered up. Error codes consist of different light patterns.
  • Page 22 Model B2000-8 B2000-7 B2000-6 B2000-5 B2000-4 B2000-3 B2000-2 B2000-1 B2000 (CURRENT) (ORIGINAL) Serial Number Beginning With Approximate 03/2014 07/2007 10/2004 03/2001 07/1997 05/1986 08/1984 01/1983 02/1982 Manufacturing Date LIMIT SWITCH SUBASSEMBLY Limit Switch Kit B2000LSK Interchangeable Interchangeable Interchangeable Interchangeable CL789103 CL789103 CL789103 CL789103...
  • Page 23 Leg and Wheels for model B2000-6 and newer has a different design from any previous models; many parts are not interchangeable. GARDNER BENDER LIMITED WARRANTY: Gardner Bender warrants its product against defects in workmanship and materials for 1 year from date of delivery to user.

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Cyclone b2000

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