Gardner Bender B2000 Cyclone User Manual

1
GAR_TL_045_0717
Troubleshooting Guide
B2000 Cyclone
®
Bender
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.
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
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
10.0 Interchangeable Part Compatibility ..............21-23
REQUIRE TOOLS AND TEST EQUIPMENT
• Torque Wrench
• Allen Wrench
• Open Wrench ½" and 9/16"
• Sockets
• Lithium Grease
• Soft Head Mallet
• 2" EMT and Rigid Conduit
• Silicone sealant
• Multimeter
• Strap Wrench
• Repair Parts Sheet
• Instructions Manual
TABLE OF CONTENTS
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.

Gardner Bender B2000 Cyclone Specifications

General

Brand	Gardner Bender
Model	B2000 Cyclone
Category	Power Tool
Language	English

Summary

Troubleshooting Guide

Bending Shoe Movement Issues

Troubleshoot bending shoe movement issues.

Conduit Locking Problems

Troubleshoot conduit locking issues with roller housing.

Incorrect Roller Installation

Identify and resolve issues with incorrect roller installation.

Damaged Rollers

Address problems caused by damaged rollers.

Loose Drive Belt Tension

Troubleshoot loose drive belt tension.

Bend Switch Malfunction

Diagnose issues when bend switch fails but return switch works.

Return Switch Malfunction

Diagnose issues when return switch fails but bend function works.

Inoperative Remote Pendant Switch

Troubleshoot inoperative remote pendant bend switch or wiring.

Bend Limit Switch or Harness Issues

Diagnose malfunctioning bend limit switch or harness.

Bend Limit Switch Plunger Not Tripped

Address bend limit switch plunger not being tripped by shoe post.

Printed Circuit Board Malfunction

Troubleshoot malfunctioning printed circuit board.

Pendant Return Switch Malfunction

Diagnose malfunctioning pendant return switch.

Wiring Malfunction

Troubleshoot malfunctioning wiring.

Bender Shoe Return Failure

Troubleshoot bender shoe not returning with return/jog button.

Jog Button Malfunction

Diagnose malfunctioning jog button.

Damaged Pendant Wire Harness

Troubleshoot damaged wire harness to pendant.

Damaged or Malfunctioning Pendant

Diagnose damaged or malfunctioning pendant.

Zero Limit Switch Voltage Issues

Troubleshoot zero limit switch voltage issues.

Harness to Switch Voltage Issues

Diagnose malfunctioning harness to switch voltage issues.

Consistent Over Bending

Address consistent over bending issues.

Incorrect Bend Angle Indication

Troubleshoot incorrect bend angle indications.

Zero Adjustment Required

Perform necessary bender zero adjustments.

Angle Adjustment Required

Perform necessary bender angle adjustments.

Pendant (P05C) Troubleshooting

Test Zero Light

Test the zero light function using a multimeter.

Test Power LED

Test the power LED function using a multimeter.

Test Bend Button

Test the bend button function using a multimeter.

Test Return Button

Test the return button function using a multimeter.

Test Jog Button

Test the jog button function using a multimeter.

Disassembly Instructions

Limit Switch Disassembly

Instructions for disassembling the limit switch assembly.

Roller Housing Disassembly

Instructions for disassembling the roller housing.

Bender Shoe Disassembly

Instructions for disassembling the bender shoe.

Circuit Board Disassembly

Instructions for disassembling the circuit board.

Electric Motor Disassembly

Instructions for disassembling the electric motor.

Reassembly Instructions

Drive Belt And Sprockets Reassembly

Instructions for reassembling drive belt and sprockets.

Drive Sprocket Assembly Reassembly

Instructions for reassembling drive sprocket assembly.

Motor Assembly Reassembly

Instructions for reassembling the motor assembly.

Shoe Shaft Reassembly

Instructions for reassembling the shoe shaft.

Roller Housing Reassembly

Instructions for reassembling the roller housing.

Printed Circuit Board Reassembly

Instructions for reassembling the printed circuit board.

Limit Switch Assembly & Wiring Reassembly

Instructions for reassembling limit switch assembly and wiring.

Zero Set Adjustment

Maintenance

L.E.D. Location

Location and function of the diagnostic L.E.D. on the circuit board.

Interchangeable Part Compatibility