Bender Head Disassembly - Greenlee 855 Service Manual

Bender Head Disassembly
Disconnect power supply before
servicing bender. The bender head
should be serviced/disassembled
while on the trunnion base.
Failure to observe this warning could
result in severe injury or death.
Electronics
Note: Refer to the "Electrical Control System Layout
and Parts List" for the location of key numbers.
Power Generation Board (PGU)
1. Remove the four screws securing the top round
cover, and remove the cover.
2. Disconnect the ground jump wire (28) and the white
and black leads of the Power AC Wire Unit (21).
3. Disconnect the power cord neutral (white) wire (3).
4. Disconnect the power lead (black) from the switch (1).
5. Disconnect the PGU-I/O cable (13).
6. Disconnect the motor leads (2).
7. Remove the four screws securing the PGU subplate
and remove the assembly.
8. Assemble in reverse order, noting the proper polarity
of all wires as shown.
Rectifier
1. Remove the PGU subplate by following steps 1 to 7
under "Power Generation Board" disassembly above.
2. Disconnect the red, black, and two yellow wires
to the rectifier (18, 19, 20).
3. Remove the screw, lock washer, and nut securing
the rectifier.
4. Assemble in reverse order, using heat transfer
grease between the rectifier and subplate.
Relay
1. Remove the PGU subplate by following steps 1 to
7 under "Power Generation Board" disassembly
above.
2. Disconnect the red and black PGU-relay wires
(11, 12).
3. Disconnect the relay wire unit (8).
4. Remove the red and black relay wires (9, 10).
5. Remove the two screws, lock washers, and nuts,
and then remove the relay.
6. Assemble in reverse order.
Greenlee / A Textron Company
See Electrical Control System Layout for location of key numbers.
Input/Output Board (I/O)
1. Remove the four screws securing the top cover and
remove the cover.
2. Disconnect the receptacle unit (4).
3. Disconnect the selector switch (22).
4. Disconnect the unload lockout switch (7).
5. Disconnect the limit switch (5).
6. Disconnect the optical encoder (23).
7. Disconnect the brake wire (6).
8. Disconnect the PGU-I/O cable (13).
9. Disconnect the Power AC Wire Unit (21).
10. Remove the four screws securing the I/O subplate
and remove the assembly.
11. Assemble in reverse order, noting the proper polarity
of all wires as shown.
Chain
If the chain breaks, replace it with new chain
(90542509)—not another master link. Because of the
high stress on the chain, the 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).
1. Remove the four screws securing the top cover and
remove the top cover.
2. Remove the 1-1/2" to 2" shoe (refer to "Changing
Shoes" in the "Maintenance" section of this
manual).
3. Remove the seven screws securing the front guard
and remove the guard.
4. Remove the nine screws securing the motor cover
and remove the motor cover.
5. Rotate the motor until the chain master link is
accessible at the top of the bender.
6. With the bender head in the horizontal position,
loosen the four bolts and nut securing the motor
and turn the eccentric adjusting bolt to allow chain
slack.
7. Tap the motor toward the spindle to slack the chain,
taking care not to allow the encoder to contact the
frame.
8. Remove the cotter pins, master link, and chain.
9. Reassemble in reverse order, noting the following:
• Torque the eccentric adjusting bolt to 81 Nm
(60 ft-lb) while tightening the two front bolts and
nut to maintain chain tension.
• Use a new master link and cotter pins.
11
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
855 Smart Bender
®