7
3.0 DISASSEMBLY INSTRUCTIONS
IMPORTANT: To avoid unnecessary service, the bender
should be tested prior to any service work. Please refer
to the maintenance section in the instructions manual and
Troubleshooting section.
Limit Switch (Figure 3)
1. Prior to removing components of the limit switch
and angle adjustments, the bending shoe, trip ring
and sprocket housing must be marked to aid in
re-assembly.
2. Position the bending shoe to the zero point by
pressing the pendant in “RETURN. Continue holding
the switch until the shoe stops and the zero light
comes on.
3. Unplug the bender power cord.
4. Scribe a mark on the side of the trip ring (Figure 1)
and a matching mark on the bending shoe.
5. Scribe a mark on the lower portion of the bending
shoe and on the sprocket housing (Figure 1).
6. Remove the silicone packing from the trip ring
mounting screws (Figure 3). Remove the mounting
screws and the top plate assembly (Figure 3), the size
indicator plates must not be removed.
7. Remove and tag the wires attached to the limit
switches (Figure 3). Leave the switches (Figure 3)
attached unless they require replacement.
8. Remove the springs and the three screws from the
plate assembly (Figure 3).
9. Leave actuator and clamp attached to upper plate
assembly unless damaged.
10. Examine all components for signs of wear or damage.
Use troubleshooting procedures to electrically check
switches. Repair or replace items that are worn,
damaged or non-functional.
11. Refer to “RE-ASSEMBLY” section of this manual.
Roller Housing (Figure 4 & 5)
1. Remove the pin (Figure 5 Item #6) securing the upper
roller arm (#5). Remove the nut (Figure 5 Item #10)
and remove the cap screw (Figure 5 #9) securing the
arm in the Cam Shaft (Figure 5 Item #7).
2. Remove the cap screw (Figure 5 Item #12) and the
washer (Figure 5 Item #13). Lift the roller housing
(Figure 4 Item #1) from the shaft. Remove the thrust
washers (Figure 1 Item #21) and the shims (Figure 1
Item #22).
3. Inspect all rollers, the housing and shaft for wear and
damage. Replace worn or damaged items.
4. All nylon rollers should be secured in the housing by
retaining rings around the roller shafts (Figure 4). Be
sure that the correct rollers are reassembled in the
exact location they were in originally. All new rollers
contain factory installed bearing.
Bender Shoe (Figure 1 & 2)
1. Prior to removing the bending shoe, the limit switch
assembly must be removed. Refer to “LIMIT SWITCH”
in the disassembly procedures.
2. Remove the four bolts (Figure 1 Item #9) and washers
(Figure 1 Item #10) located on the flat portion of each
side of the shoe (Figure 2 Item # 1).
3. Two people are required to lift the bending shoe. Lift
at two places (180° apart) and pull the shoe straight
up until it clears the shoe shaft.
4. Inspect the shoe for worn grooves, cracks or other
damage. Each conduit groove should be checked for
wear by placing a piece of conduit (of correct size and
material) into the groove. It should fit easily without
excessive gaps above, below or behind it.
5. If shoe damage is suspected, a dye penetrate may be
required to locate cracks in the casting.
6. Refer to Re-Assembly procedures.
Circuit Board (Figures 7 / Insert B)
1. The printed circuit board is mounted inside of the
sprocket housing. Access is gained by removing the
handle assembly.
WARNING: To avoid electrical shock, unplug the
bender power cord prior to removing the handle and
access plate.
2. Remove the four screws and washers (Figure 7 Items
#13 & 17).
3. Remove the handle assembly (Figure 1 Item# 38)
NOTE: Hold the handle to prevent it from falling and
causing damage to electrical connectors inside the
sprocket housing.
4. Lower the handle and plate assembly. Unplug the
power cord receptacle (Figure 7 Item #3) from the
P.C. board plug. Unplug the pendant receptacle (Fig.
7 Item #7) from the P.C. board plug.
5. Conduct testing procedures described in the
“Troubleshooting” section. See Insert B for wiring
diagram.
Electric Motor (Figure 6)
WARNING: Unplug bender power cord prior to removing
motor or wiring.
1. Remove acorn nuts securing the motor bottom cover.
2. Remove electrical wires from bottom of motor. Refer
to (Page 14 Insert A).
3. Remove bolt and washer (Figure 6 Item #26 & 27)
which secures the locking plate (Figure 6 Item #37)
to the bottom of the sprocket housing. Remove bolt
(Figure 6 Item #38), lock washer (Figure 6 Item #39)
and washer (Figure 6 Item #40) which secures the
sprocket shaft in the locking place.
4. Rotate the sprocket shaft by placing the locking plate
over the shaft flats. Turn the shaft until the sprocket
belts and chains are loose.
5. Remove the conduit nut (Figure 6 Item #15) from the
motor connection. Slide the flexible conduit out of the
