45 Bender Operation Manual
SYMPTOM / CONDITION POSSIBLE CAUSE CORRECTIVE ACTION
The motor does not run Circuit breaker(s) is off Turn breaker(s) on
Incorrect wiring. Check voltage supply, phase and wiring. Refer to
wiring instructions found on pages 49-50
Heater in switch box has been tripped. Check thermal heaters(s) See page 44.
Defective electric starter / motor. Test and replace as needed.
The motor smokes. Power supply incorrect. Check voltage supply, phase and wiring. Refer to
wiring instructions found on pages 7 & 43
The motor shuts off. Thermal overload tripping. Check voltage supply, phase and wiring. Refer to
wiring instructions found on pages 7 & 43. If prob-
lem persists, check wiring for short circuits. Check
amp draw. Refer to motor nameplate.
The bender gives off shocks. The plug has been wired wrong.
Power is connected to the ground
wire.
Check plug. Make sure that the green wire on the
power cord is used for grounding purposes only.
NO POWER should be connected to the green
ground wire.
Power wire has become disconnected
in the switch box or motor.
Check all connections.
The tubing wrinkles or kinks. Incorrect guide plate alignment, worn
barrel bushings or pusher block.
Tubing gauge is not adequate for that
particular size or radius.
See page 48 for improving bend quality.
The bender experiences loss of
power. The motor stalls even though
the system pressure is showing
less than 2000 psi.
Incorrect wiring. Voltage or amperage
too low.
Check voltage supply, phase and wiring. Refer to
wiring instructions found on pages 7 & 43.
BA / BAS models - Bending ram will
retract with the button controls but
not with the left foot switch.
Left foot switch is inoperative or wire
has become disconnected
Check connections on micro switch. Refer to
diagrams on pages 49-50. Check micro switch with
ohmmeter. See page 43. Check for broken or
disconnected wires.
BA / BAS models - The top cylinder
will advance with the button
controls but not with the right foot
switch.
Right foot switch is inoperative or wire
has become disconnected
Check connections on micro switch. Refer to
diagrams on pages 49-50 Check micro switch with
ohmmeter. See page 43. Check for broken or
disconnected wires.
The sequence valve pressure
surges high when trying to retract
the bending ram.
The return pressure is set too high.
The top cylinder is trying to overcome
the bottom cylinder which is not
retracting simultaneously
Adjust return pressure as shown on page 33.
The back gates remain in the open
position even after the bending ram
is retracted.
Tubing is not sliding back with the
radius die after the bend is made,
causing the gates to remain open.
Clean and thoroughly grease bending dies
before use. Wipe tubing clean.
Return pressure is set too low. Adjust return pressure as shown on page 33.
The swager cylinder does not
expand the tubing straight.
The swager cylinder is not aligned
correctly.
Shim the swager cylinder as required. See
page 37.
The swager cylinder is bent. Remove and replace swager cylinder
Bender Operation Manual 45
TROUBLESHOOTlNG
Introduction;
The troubleshooting procedures shown on the following pages contain certain systems and/or conditions, possible causes
and the corrective actions required. The chart gives the easiest corrective action first, then proceeds with more difficult procedures.
Be certain that the person(s) working on the machine have the ability to do the service. Only certified electricians should
work on electrical components. ALWAYS unplug the machine before servicing.
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