5
Bender consistently
develops over bends
Braking resistor on P.C.
board is malfunctioning.
Unplug bender power cord. Perform resistance measurements on braking
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” in “DISASSEMBLY” section (page 7) for instructions.
P.C. board circuit is
malfunctioning.
Remove and replace P.C. Board, Part Number- EC2006 or HC12.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Bender does not stop
at selected bend angle.
Bender is incorrectly
set up.
Ensure bender angle adjustment and zero adjustment has been performed.
This is required after every re-assembly.
Refer to “ZERO SET ADJUSTMENT” section (page 10) for mechanical
adjustment instructions. Refer to Instruction Sheet for Angle Adjustment
instructions and correct set up instructions.
Bend limit switch is not
being actuated by shoe
post.
Remove shoe indicator plate. Observe the tabs as they pass the bend limit
switch.
Adjust switch until tabs correctly contact the posts.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Bend limit switch is
malfunctioning.
Unplug the bender power cord. Attach leads to orange and green wires at the
switch. Continuity should exist. Push the actuator tab (on the switch).
Continuity should be broken. If not, replace the switch.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Braking resistor is
malfunctioning.
Unplug the bender power cord. Perform resistance measurement on braking
resistor. Attach leads across terminals.
A 9-11 ohms (+ 1 ohm) resistance is normal. Other readings are unacceptable.
Replace braking resistor, Part Number – RA19.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Brake circuit (P.C. board)
is malfunctioning.
If all other tests are positive, replace P.C. board, Part Number– EC2006
or HC12.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
During return function,
bender shoe does not
stop at zero point.
Plunger on return
limit switch is not
being tripped by the
trip ring tab.
Remove limit switch assembly. Observe tab to return limit switch contact.
If switch is not contacting tab, adjust switch position.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Bend limit switch is
malfunctioning.
If post to switch is correct, perform bend limit switch continuity check. Attach
leads to orange and green wires. Press limit switch tab.
Continuity should result. If not, replace switch.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Return limit switch is
malfunctioning.
Unplug the bender power cord. Perform return limit switch continuity check.
Attach leads to white and blue wires.
Continuity should be broken. If not, replace return limit switch.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
Brake resistors are
malfunctioning.
Unplug the bender power cord. Perform resistance measurement on each
resistor. Place ohm meter leads on gray and brown wires.
Meter should read 9-11 ohms. If reading is over 11 ohms, replace resistor.
Refer to “Circuit Board” in “DISASSEMBLY” section (page 7) for instructions.
Bender shoe does not
stop rotating in both
the return and bend
directions.
Limit switches
assembled incorrectly
on the switch arm.
If the Limit Switch has been disassembled in the past, the switches may have
been reassembled incorrectly on the switch arm. The switch arm must have
two limit switches (blue face, facing away from arm) on the long side of the
arm, and one limit switch (black face, facing away from arm) on the short side
of the arm.
Refer to “Limit Switch” in “DISASSEMBLY” section (page 7) for instructions.
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