Troubleshooting - Greenlee 854 Service Manual

Troubleshooting (cont'd)
The following flow charts show the suggested trouble-
shooting procedures for some bender problems. They by
no means encompass all possible problems or solutions.
Electric shock hazard:
• Contact with live circuits can result
in severe injury or death.
• Some troubleshooting steps
require power to the bender.
This type of troubleshooting
step should only be performed
at authorized Greenlee service
centers by personnel who are
familiar with safe troubleshooting
procedures.
Failure to observe these warnings
could result in severe injury or death.
Won't bend
Is 115 VAC measured at
PGU board input?
YES
Does the green LED on
the I/O board light?
YES
Are metal oxide varistors
(MOVs) on PGU board
damaged or discolored?
NO
Does the green LED on
the PGU light?
YES
Does amber or red LED
on I/O light when BEND
or UNLOAD is pressed?
YES
Does relay on I/O
operate when BEND or
UNLOAD is pressed?
YES
Replace PGU.
Greenlee / A Textron Company
Plugged into dead circuit,
NO
bad power cord, or
switch is bad or off.
NO
Replace I/O board
assembly.
YES
Replace PGU.
NO
Replace PGU.
Unplug pendant or I/O and
NO
check switch for continuity.
If ok, replace I/O.
NO
Replace I/O.
Trips circuit breaker
Are the proper support rollers
and shoe groove being used
for the type and size of conduit
being bent?
YES
Is the current on the 115 VAC line
exceeding 20 amps?
YES
Is the DC current to the motor
exceeding 17 amps?
NO
When BEND is pressed, is the
voltage sent to the motor 20 to 50
volts over the AC line voltage?
YES
Are connectors corroded?
NO
Replace PGU.
Won't stop
Is the supply line voltage low?
NO
Does bender stop when the
pendant is unplugged?
NO
Replace PGU.
Bender only runs in one direction
On 854 move pendant plug to
I/O board. Does bender run both
directions?
NO
Does amber or red LED light when
switch is pressed?
YES
When amber or red LED is on, is
12 VDC measured at large relay
coil on PGU (where relay wire
unit connects)?
NO
Move 6-wire connector on PGU
from "TO I/O" to "TEST." Alternately
press BEND and UNLOAD. Does
yellow "DIRECTION" LED on PGU
turn on and off?
YES
Replace PGU.
11
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
854 Quad Bender
NO
Follow directions in
instruction manual.
NO
Replace circuit
breaker.
YES
Replace motor.
Replace bridge
NO
rectifier
(91859972).
YES
Clean.
YES
Use 115 VAC.
Replace pendant
YES
switch.
YES
Replace direction
switch assembly.
NO Check and replace
pendant switch.
YES
Replace
91866456 relay.
NO
Replace I/O.