Troubleshooting Guide
B2000 Cyclone® Bender
GAR_TL_045_0515
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.
SAFETY ISSUES
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.
WARNING: 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.
CAUTION: Keep hands, clothing and electrical power cords away from moving rollers, bending shoe and
exposed gears.
IMPORTANT: Prior to installation: apply a coat of molycoat or equivalent to all shafts. When installing
shafts, use soft head mallets to seat in position.
REQUIRE TOOLS AND TEST EQUIPMENT
•
•
•
•
•
•
Torque Wrench
•
•
•
•
•
•
2” EMT and Rigid Conduit
Silicone
Allen Wrench
Open Wrench ½ “ and 9/16 “
Sockets
Multi-meter
Strap Wrench
White Assembly Grease
Soft Head Mallet
Repair Parts Sheet
Instructions Manual
TABLE OF CONTENTS
1.0 Troubleshooting Guide............................................2
2.0 Pendant Troubleshooting........................................4
3.0 Disassemble Instructions .......................................5
Limit Switch........................................................5
Roller Housing....................................................5
Bender Shoe.......................................................5
Circuit Board.......................................................5
Electric Motor.....................................................5
Drive Sprocket Assembly...................................6
4.0 Reassembly Instructions ........................................6
Drive Belt and Sprockets...................................6
Motor Assembly .................................................7
Shoe Shaft ..........................................................7
Roller Housing....................................................7
Prinited Circuit Board.........................................7
5.0 Zero Adjustment......................................................8
6.0 Parts Breakdown.....................................................9
B2000 Bender.....................................................9
Bottom of Electric Motor .................................10
Shoe..................................................................11
Limit Switch......................................................12
Roller Housing..................................................13
Upper Roller / Handle ......................................14
Sprocket Housing.............................................15
Handle / Control Circuit ...................................16
7.0 Wiring Schematic..................................................17
8.0 B2000 Wiring Diagram..........................................18
9.0 Maintenance..........................................................19
Limit Switch Assem/Wiring
7
1
PROBLEM
POSSIBLE CAUSE
ACTION
Bender does not
stop at selected
bend size (angle).
Bend limit switch is not being actu- Remove shoe indicator plate. Observe the tabs as they
ated by shoe post
pass the bend limit switch. Adjust switch until tabs cor-
rectly contact the posts.
Bend limit switch is not functioning 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.
Breaking resistor is not functioning
Unplug the bender power cord. Perform resistance mea-
surement on breaking resistor. Attach leads across termi-
nals. A 9-11 ohms (+ 1 ohm) resistance is normal. Other
readings are unacceptable. Replace breaking resistor,
Part Number - DA7034380.
Brake circuit (P.C. board) not func-
tioning
If all other tests are positive, replace P.C. board, Part
Number - DA7034380.
During return func-
tion, bender shoe
does not stop at zero
point.
Plunger on return limit switch is not Remove limit switch assembly. Observe tab to return lim-
being tripped by the trip ring tab
it switch contact. If switch is not contacting tab, adjust
switch position.
Bend limit switch is not
functioning
If post to switch contact 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.
Return limit switch not
functioning
Perform return limit switch continuity check. Attach leads
to white and blue wires. Continuity must exist when
pressing actuator tab. If not replace return limit switch.
Brake resistors not functioning
Unplug 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 resistors.
Bend function works, Direction circuit, on P.C. board not
Replace P.C. board.
return function
results in bending
direction.
functioning
Return function
works, bend func-
tion results in shoe
moving in return
direction.
Brake circuit on P.C. board not
functioning
If all other tests are positive, replace P.C. board.
Return function
Direction circuit, on P.C. board, not Replace P.C. board
functioning
works. Depressing
bend switch, shoe
moves in return.
3
2.0 PENDANT (P05C) TROUBLESHOOTING
1. Verify continuity for both wires traveling from the zero limit switch down to the wire harness.
ZERO STOP SWITCH
BEND LIMIT SWITCH
RETURN LIMIT SWITCH
BLACK
Typical Switch Contacts
COMMON
GREEN
WHITE
RED
(OPEN)
(OPEN)
ORANGE
NORMALLY OPEN
BLOCK MOUNTING
BLUE
NORMALLY CLOSED
(OPEN)
Y
2. Verify that the black wire goes to the pin on the limit switch that is separate from the other two, and that the red wire
is connected to the middle pin.
3. Test Zero Light - Take a multimeter and set it to the diode (
) function and place the red lead on the orange wire
in the harness and the black lead to the red (pink) wire in the harness. This should illuminate the green Zero LED
4. Test Power LED - Take a multimeter and set it to the diode (
) function and place the red lead on the orange wire
and black lead on the yellow wire. This should illuminate the red Power LED.
5. Test Bend Button - Set a multimeter to the continuity or ohms function. Place one meter lead to the pin of the Black
wire in the pendant wire harness, and place the other lead on the pin for the Blue with Black strip wire. While the
probe tips are making contact with the pins in the harness, press the bend button. When the button is pressed, 0
Ohms and/or the continuity buzzer should go off.
6. Test Return Button - Set a multimeter to continuity or ohms function. Place one meter lead on the pin of the Black
wire in the pendant wire harness. Place the other meter lead to the pin of the Blue wire in the harness. With the
probes still making contact with the pins, press the Return button. When the button is pressed, 0 Ohms and/or the
continuity buzzer should go off.
7. Test Jog Button - Set a multimeter to the continuity or Ohms function. Place one meter lead to the pin of the Black
wire in the pendant wire harness, and place the other lead on the pin for the Brown wire. While the probe tips are
making contact with the pins in the harness, press the bend button. When the button is pressed, 0 Ohms and/or the
continuity buzzer should go off.
4
3.0 DISASSEMBLY INSTRUCTIONS
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.
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.
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.
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.
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.
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.
5. If shoe damage is suspected, a dye penetrate may be
required to locate cracks in the casting.
3. Unplug the bender power cord.
6. Refer to Re-Assembly procedures.
4. Scribe a mark on the side of the trip ring (Figure 1)
and a matching mark on the bending shoe.
Circuit Board (Figures 7 / Insert B)
5. Scribe a mark on the lower portion of the bending
shoe and on the sprocket housing (Figure 1).
1. The printed circuit board is mounted inside of the
sprocket housing. Access is gained by removing the
handle assembly.
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.
WARNING: To avoid electrical shock, unplug the
bender power cord prior to removing the handle and
access plate.
7. Remove and tag the wires attached to the limit
switches (Figure 3). Leave the switches (Figure 3)
attached unless they require replacement.
2. Remove the four screws and washers (Figure 7 Items
#13 & 17).
3. Remove the handle assembly (Figure 1 Item# 38)
8. Remove the springs and the three screws from the
plate assembly (Figure 3).
NOTE: Hold the handle to prevent it from falling and
causing damage to electrical connectors inside the
sprocket housing.
9. Leave actuator and clamp attached to upper plate
assembly unless damaged.
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.
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.
5. Conduct testing procedures described in the
“Troubleshooting” section. See Insert B for wiring
diagram.
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).
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 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).
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.
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.
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
5
elbow and pull the wires out.
4.0 RE-ASSEMBLY INSTRUCTIONS
6. Remove the rear access plate by removing 4 cap
screws and washers.
Drive Belt And Sprockets (Figure 6)
7. Remove the four cap screws and washers (Figure 6
Item #18 & 19) securing the motor to the sprocket
housing, Remove the motor, unhook the drive belt
from the motor shaft.
1. Position drive belt sprocket (Figure 6 Item #24) and
shoe sprocket (Figure 6 Item #29) on a flat surface.
Connect 3/8” chain (Figure 6 Item #10) to drive belt
sprocket (upper gear) and to shoe bracket (large
lower gear). Insert master link (pin up).
8. Remove the belt tensioner (Figure 6 Item #2) by
removing nut and washer. The tensioner shaft is
spring loaded. Remove the tensioner assembly
spring and shaft from inside the sprocket housing.
2. Lift the belt sprocket, slip the belt (Figure 6 Item # 1)
under the sprockets and position it in the sprocket
grooves. Lift the shoe sprocket, position the belt so it
is around sprocket shaft boss (Figure 6).
Drive Sprocket Assembly (Figure 6)
3. Pull the belt tight around the belt sprocket. Fasten
the loose end together with a rubber band to keep
the belt snug on the sprocket.
1. Separate the drive chain (Figure 1 Item #8) by
removing the master link.
4. Insert drive sprocket (Figure 6 Item #34) into the
housing (large gear up) and position the gear through
the hole (under bracket). Place small blocks between
the gear and the housing to hold the sprocket against
the inside of the housing.
NOTE: The master link is assembled with clip on top
– it must be reassembled the same way.
2. Remove drive sprocket (Figure 1 Item #7) from shoe
shaft (Figure 6 Item # 31), Remove spacer (Figure 1
Item #5) and DU Washer (Figure 1 Item #6).
5. Position shoe sprocket (Figure 6 Item #29) and belt
sprocket into the housing, from the motor end. The
belt sprocket is aligned under the drive sprocket and
the shoe sprocket is positioned under the shoe shaft
hole. The loose belt end belongs toward the motor
end of the housing. Position thrust washer (Figure
6 Item #20) between the belt sprocket and drive
sprocket, bearing surface facing up.
3. Remove dust cap (Figure 1 Item #36) from sprocket
housing.
4. Remove cap screw (Figure 6 Item #22) and washer
(Figure 6 Item #47 / 23). Lightly tap bottom of roller
housing shaft (Figure 6 Item #11) to remove it from
the sprocket housing.
NOTE: Use brass drift pin or leather mallet to remove
shafts.
6. Place the thrust washer (Figure 6 Item #20) under the
shoe sprocket.
5. Rotate sprocket (Figure 6 Item # 34) until the master
link for chain (Figure 6 Item #28) appears in the
access opening.
7. Align drive sprocket (Figure 6 Item #34) and belt
sprocket (Figure 6 Item #24) with the center hold
(under bracket on housing). Place bearing (Figure 6
Item #35) on top of sprocket. Remove blocks.
6. Remove the master link and remove the chain from
the sprocket housing.
8. Mark high point on end of sprocket shaft (Figure 6
Item #33). Lubricate shaft with light coat of general
purpose grease. Insert shaft (flats first) through the
sprockets. Drive flush with the top sprocket.
7. Remove the cap screw (Figure 1 Item #22) and
washer (Figure 1 Item #23 / 47). Carefully remove
shoe shaft (Figure 6 Item #31) by holding the limit
switch wires inside the sprocket housing and lifting
the shaft out of the housing. Remove bearing (Figure
6 Item# 21).
9. Insert cap screw (Figure 6 Item #27) through washer
(Figure 6 #26) and locking plate (Figure 6 Item
#37). Torque to 28 – 32 ft. lb. Install cap screw into
sprocket shaft under housing. Install cap screw
(Figure 6 Item #38) and washer (Figure 6 Item #39
/40) in hole aligned with lock plate slot. Torque to 19
– 21 ft. lb.
8. While removing the sprocket shaft (Figure 6 Item
#33), hold the sprocket down, tap the shaft (from the
bottom) and remove it from the sprocket housing.
9. Remove sprocket assemblies (#8) and (#9) from the
housing and remove thrust washer (#10).
10. Mark the middle link of chain (Figure 6 Item #28).
Put the chain over the small (upper) gear teeth of
sprocket (Figure 6 Item #29). Place chain around
large gear of sprocket (Figure 6 Item #34).
10. Remove sprocket assembly (#11) and thrust washer
(#12) from the housing.
11. Clean the sprocket housing (inside), wipe away
grease and dirt. Use lower pressure air hose to
remove any accumulation of debris.
11. Install master link through the access hole in the
housing (pins up).
12. Clean all sprockets, gear teeth and chains. Check
for worn gear teeth and worn or damaged bearings.
Check chains and drive belt for wear and/or damage.
Replace damaged or worn items.
12. Install tensioner assembly by inserting shaft (Figure 6
Item #1) through the inside of the sprocket housing
(threads outward). Assemble the lock washer (Figure
6 Item #2) and nut and tighten.
13. From inside the sprocket housing slide the spring
over the shaft, then slide the tension roller over the
shaft (roller toward drive belt). Place something under
the tension bracket to wedge it in place away from
the drive belt.
6
Motor Assembly (Figure 6 / Insert A)
1. Remove restraint from drive belt.
3. Place shim (Figure 1 Item #22) and washer (#21) over
the shaft. Install the complete roller housing on the
shaft. Secure with cap screw (Figure 5 Item #12) and
washer (#13).
2. Place gasket (#1) on motor flange. Insert motor into
the sprocket housing. Install one mounting screws
and washers into mounting hole closer to the belt
4. Position the upper roller arm (Figure 4 Item #11) in the
bracket and install mounting bolt (Figure 5 Item #9),
washer (#10), nut washer (#11) and pin (#6).
3. Position the drive belt over the motor pulley. Align the
belt to ride at the same height on the motor pulley
and grooved sprocket.
Printed Circuit Board (Figures 7 / Insert B)
4. Using a strap tool put it around the motor to help
align the mounting holes with the motor. Install the 3
mounting screws and washers.
1. Connect the sprocket harness receptacle to the
board plug. Connect motor wire receptacle to the
board plug.
5. Remove the wedge from beneath the tension bracket.
The roller should engage the belt.
2. Connect the pendant receptacle to the P.C. board
plug. Connect power cord receptacle to P.C. board
plug. Be sure the harness ground wires are attached
to the end plate.
6. Connect wiring to base of motor. (Figure 1 Insert B).
Shoe Shaft (Figure 6)
3. Position the handle assembly against the sprocket
housing and attach with 4 washers and screws.
1. Position the shoe shaft (Figure 6 Item #31) in the
sprocket housing (Figure 6 Item #32) with the hole for
the wiring facing the hole in the housing.
Limit Switch Assembly & Wiring (Figure 3 / Insert B)
2. Insert the D.U. bearing (Figure 6 Item #21) between
the shoe sprocket and the sprocket housing (Figure 6
Item #32).
1. Insert the four wires from the main harness into
the conduit connecter, through the conduit and
connecter (Figure 6 #16 / 17).
3. Push the shoe sprocket (Figure 1 Item #7) into the
sprocket until it rests on the housing. Install two
washers (Figure 6 Item #23 / 47) and cap screw (#22)
through bottom of housing and tighten to secure
shoe shaft. Torque 68-82 ft. lbs.
2. Attach wires to motor. See Insert A for wire colors
and terminal locations. Install motor cap using cap
nuts.
3. Pull any excess wire into the sprocket housing. Be
sure main harness is fastened to the housing with the
(J) clip.
4. Install connector into bottom of sprocket housing and
tighten. Install bushing in wire hole (housing) near the
shoe shaft.
4. Insert the limit switch wires through the plate assembly
(Figure 3 Item #9). Position the thrust washer and
plate into the bending shoe and fasten with lock
washers (Figure 3 Item #9) and cap screws (included).
5. Install limit switch wires (Figure 1 Item #3) from inside
sprocket housing, through the bushing and into the
side of the shoe shaft. Push the wires up and through
the top of the shaft. Pull at least six inches out of the
shaft.
5. Install the return limit switch and zero stop switch,
secure with screws to the switch arm (Figure 3 #7 / 8
/ 9).
6. Position shoe drive sprocket (Figure 1 Item #7) over
the shoe shaft. Install the drive chain around the shoe
sprocket and the drive sprocket (Figure 1 Item #8)
(under housing bracket).
6. Install the Bend limit switch and secure to switch arm
with screws (Figure 3 Insert B).
7. Connect wires to switches as shown in Insert B and
set the switch arm onto the plate assembly (#9).
7. Install master link, pins down. Support the sprocket
with blocks to level the chain and fasten the master
link.
8. Insert clamp assembly (#1) through the trip ring
assembly (#5) and secure the actuator (#6).
8. Place the thrust washer (Figure 1 Item #6) and washer
(#5) on the shoe shaft. Place the bending shoe over
the shaft and align the mounting holes with the
sprocket holes. Use alignment marks placed during
removal, to position the shoe on the shaft. Install four
cap screws (Figure 1 Item #9) and washers (#10) to
secure the shoe and sprocket. Torque to 68-92 ft. lbs.
9. Place the trip ring (#5) on the shoe and align the
marks scribed, during disassembly, on the trip ring
and bending shoe. Secure trip ring with screws.
Roller Housing (Figure 4 & 5)
1. Insert roller housing shaft (Figure 6 Item #11) into
sprocket housing until it seats in bottom of the
housing.
2. Secure the shaft with washer (Figure 6 Item #23) and
cap screw (Figure 6 Item #22) from the bottom of the
sprocket housing.
7
5.0 ZERO SET ADJUSTMENT
TO ENSURE ACCURATE BENDS, THE BENDER ZERO ADJUSTMENT MUST BE ACCOMPLISHED AFTER
RE-ASSEMBLY.
1. Plugs bend power cord into 110/115V outlet. Push upper roller assembly against the stop on the sprocket housing
(Figure 19).
2. Press and hold “ADVANCE” on pendant switch until RIGID side of shoe is facing the upper roller housing.
3. Place a straight edge against the shoe (clamp surface) and toward the upper roller shaft.
4. Jog the bender until 2 ½ inches exists between the straight edge and the shoe clamp (See Figure 4).
5. Loosen the trip ring mounting screws (See Figure 5). Rotate the trip ring until the zero light, on the pendant, is on
(Figure 6). Tighten the mounting screws and cover screws and cover screw slot with a clear silicone sealant.
Figure 4
Figure 5
Figure 6
8
Figure 1
B2000 Bender Assembly
2
3
9
9
23
24
12
10
10
1
21
22
38
20
7
8
36
5
6
4
27
(See Fig. 7)
35
34
34
17
35
35
34
37
26
25
14
SEE INSERT A Page 3
& Fig. 6, (page 8)
15
16
40
18
19
11
13
21
9
INSERT A
28
30
33
31
32
29
31
30
B2000 Bender Assembly, cont.
# Req’d Description
B2000 Bender Assembly
# Req’d Description
Item # Part #
Item # Part #
20
CU295900K
CK696108
1
1
4
1
Roller Housing Assm (Figure 4)
1
2
3
4
5
6
7
8
9
Figure 2, pg. 4
1
1
1
1
1
1
1
1
4
Shoe Sub Assm
21
22
23
Washer
Figure 3, pg. 5
CL712647SR
SHM115
Limit Switch Assm
Cable, Limit and Switch
Sprocket Housing
Washer, Shoe
CL229248
Shim
3
Common Repl.
Part
⁄8” -16 x 1” g. Low Carbon Hex Head
Cap Screw Zinc plated
5
24
Common Repl.
Part
1
⁄16” Zinc plated USS Flat Washer
CL157108
CL221108
CL170228
CL333066
Washer, Thrust
Shoe Sprocket
Chain
25
26
27
28
29
30
31
32
33
34
EC2006
1
1
1
1
1
2
2
1
1
8
Relay Control Assm (Figure 9)
End Plate (incl. 34 & 35)
LP204
HC12
Handle & Ctrl Ckt Assm (Figure 7)
Wire Assembly (See Above)
Wire Assembly (See Above)
Push-on Connector (See Above)
Ring-Tongue Connector (See Above)
Wire Assembly (See Above)
Wire Assembly (See Above)
3
1
Common Repl.
Part
⁄8”-24 x 2- ⁄2 Grade 5 Zinc Plated
call tech support
call tech support
E1001104
Hex Cap Screw
3
10
Common Repl.
Part
4
⁄4” plu SAE Flat Washer
11
12
13
14
15
16
17
18
19
LA205
1
1
2
1
1
1
2
2
2
Leg Assembly (incl. 13, 19 & 21)
Upper Roller and Handle (Figure 5)
Casters Assm (Hardware incl.)
Locking Pin
E1001021
CK994900
CB208
call tech support
call tech support
1
7
CL185061
CL183110
F57044
Common Repl.
Part
⁄2”-13 x ⁄8” Alloy Plain Finish Socket
Head Cap Screw
Spring
1
35
Common Repl.
Part
8
⁄2” Plain Finish High Collar Lock Washer
Ring
M00084
WB207
Screw, Shoulder
36
37
38
CM129006
LK15
1
2
1
Seal
Wheel Assm (incl. 19 & 21)
Decal Kit
Rear Handle
3
1
Common Repl.
Part
⁄32” x 1- ⁄4” Zinc plated cotter pin
H905
10
Figure 2
Shoe Subassembly
8
2
10
11
4
9
3
1
4
6
5
7
7
8
Shoe Subassembly
# Req’d Description
Item # Part #
1
2
3
4
CL199809K
1
1
1
6
Shoe Bending (Incl. items 7, 8, 9 and 10)
Clamp, IMC (Incl. items 4, 5, 6)
Clamp, EMT (Incl. items 4, 5, 6)
Shoe Subassembly, cont.
# Req’d Description
CN542005
CN541005
Item # Part #
7
8
CK691061
CL61107
2
2
1
1
2
Pin
5
1
Common
⁄8” -18 x 2 ⁄4” Plain Alloy Socket Head
Bearing (includes 2)
Instruction Decal - Stub-Up
Instruction Decal - Offset
Insert, Shoe
Replaceable Part
Cap Screw
9
CM126026
CM127026
CM627028
5
5
6
Common
6
6
⁄8” Plain Finish Medium Split Lock
10
11
Replaceable Part
Washer
5
Common
⁄8” -18 Low Carbon Plain Finish
Replaceable Part
Finished Hex Nut
11
Figure 3
Limit Switch Assembly
1
1
2
B2000CK
Clamp kit
Limit Switch Assembly
Item #
Part #
Description
CM802950N Knob Sub Assembly Kit
1
Clamp Kit
3
4
CM7B62701000H8CK
ZCM793055NWasher
Thread Locker (for #1) not pictured
2
3
CM8C0M1890520950N UppKenroPblSautbeAsAsesmseblmy Kbitly
2
3
(Incl. #10
& #11)
CM767108
5
6
7
8
B2000-TRK
Trip WRianshgerAssembly Kit
CM801950
Upper Plate Assembly
4 CM803950N Actuator Kit
5
6
7
B2000-TRK
Trip Ring Assembly Kit (Incl. #10 & #11)
B2000LSK
Limit Switch Kit
CM803950N
Actuator Kit
DA9687372
Limit Switch (3-Pack)
B2000-LSK
Limit Switch Kit
10 CM593026
Pipe size decal EMT
8
DA9687372
Limit Switching (3-Pack)
9
Plate Assembly Kit
11 CM594026
CM797950KWPipe size decal Rigid/IMC
12 1Z0CF679220
Plate Assembly Kit
CM593026
Pipe size decal EMT
11
12
CM594026
ZCF679220
Pipe size decal Rigid/IMC
Springs
4
10
5
11
6
12
9
1
8
8
8
7
12
Figure 4
Roller Housing Assembly – CU295900K
11
3
13
9
2
12
3
6
9
7
NOTE: Item 11 is a separate
assembly not included with the
roller housing (Figure 5).
2
1
8
7
5
4
5
10
Roller Housing Assembly-CU295900, cont.
10
Item # Part #
# Req’d
Description
7
1
9
CU300281
2
2
1
1 ⁄4” Roller (Set of 2)
7
10
11
CU297104
CK994900
Shaft, Roller
Roller Housing Assembly-CU295900K
Upper Roller Assm
(see Figure 5)
Item # Part #
# Req’d
Description
∗
1
2
3
CU296037K
1
2
Housing, Roller
12
13
DC694104
CL343550
1
1
Axle
CL61107
Bearing
Grip, Handle
7
Common Repl.
Part
⁄8” External Retaining Ring
B2000-RK Kit includes:
Roller and Ring Kit
Part#
Qty
1
4
5
6
7
CU299281
CU298281
CN452104K
1
2
1
4
1 ⁄2” Roller
1
1 ⁄2” Roller
#4
#5
1
2
2” Roller (Set of 2)
2” Roller (Set of 2)
Shaft, Roller
1
#8
#9
#3
#7
1
2
2
4
1 ⁄2” Roller
7
Common Repl.
Part
⁄8” Carbon Spring Steel E-Clip
1
1 ⁄4” Roller (Set of 2)
7
1
⁄8” External Retaining Ring
8
CU319281
1
1 ⁄2” Roller
7
⁄8” Carbon Spring Steel E-Clip
∗When the housing is ordered, the bearings will be pre-installed.
13
Figure 5
Upper Roller and Handle Assembly – CK994900
4
1
2
3
10
4
11
9
5
6
12
7
13
Upper Roller and Handle Assembly-CK994900
Item # Part #
# Req’d Description
1
Common Repl.
1
1” External Retaining Ring
Part
8
2
CK569108
CK575281K
CK295107
CL30900
1
1
2
1
1
Washer
1
3
⁄
2”-1” Roller
∗
∗
4
5
6
Bearing (Set of 2)
Roller Axle Assembly
8
3
Common Repl.
Part
⁄8” x 3” Zinc Coherless Hitch Pin
7
CL662950KW
CK693107
1
2
1
Cam Shaft
8
9
Bearing (Set of 2)
3
Common Repl.
Part
⁄8” -16 x 3” A307A Low Carbon
Zinc Plated Hex Bolt
3
10
Common Repl.
Part
1
⁄8” - 16” Lock Nut- Nylon
11
12
Order Kit LK15
1
1
Decal, Caution
3
Common Repl.
Part
⁄8” - 16 x 1” 1g. Low Carbon Hex
Head Cap Screw, Zinc Plated
5
13
Common Repl. Part
1
⁄16” Zinc Plated USS Flat Washer
∗ These items come with bearings installed.
14
Figure 6
33
36
31
Sprocket Housing
Assembly - DA7058900
11
32
42
43
2
21
44
45
19
35
34
28
23
48
30
47
20
29
22
37
40
26
47
23
12
39
27
38
41
19
15
46
13
22
10
24
18
25
20
16
14
1
17
Sprocket Housing Assembly - DA7058900
Sprocket Housing Assembly - DA7058900, cont.
Item # Part #
# Req’d
Description
Item # Part #
# Req’d
Description
1
2
CL310014
CL306900
1
Drive Belt
Includes:
Tensioner Assembly
Snap Ring
Roller
25
26
27
CL53107
CL12108
2
1
1
Bearing
Washer
3
1
1
1
1
1
1
1
1
1
1
1
1
1
Common Repl.
⁄8” - 16 x 2” Grade 5 Zinc Plated
Part
Hex Cap Screw
Chain, .625 Pitch
Sprocket Assembly w/ Bearings
Bearing
28
29
30
31
32
33
34
35
36
37
38
CL334066
CU542950K
1
1
2
1
1
1
1
2
1
1
1
∗
∗
Bearing
CL670107
CU674104
SHM115
CL309104∗
CL667950KW
CL53107
Washer, Thrust
Tensioner Weldment
Spring
Shaft Tensioner
Nut, .375-16
Chain, .375 Pitch
Shaft, Roller Housing
Gasket, Motor
Screw (10-32)
Shaft, Shoe
Housing, Sprocket
Shaft, Sprocket
Sprocket Assembly w/ Bearings
Bearing
10
11
12
13
CL335066
CW172104
C550357
CL224028
CL669101
Stop Screw
Locking Plate
5
Common Repl.
⁄
16” - 24 x 1⁄2” LG Grade 5 Med.
Common Repl.
Part
Carbon Stl. Zinc Plated
Part
5
39
40
Common Repl.
Part
1
1
⁄16” Zinc Plated USS Flat Washer
14
15
16
17
18
CL43259
1
1
1
1
4
Motor Assembly
Connector
Conduit, Flexible
CL674096
CL673228
CL675096
1
Common Repl.
⁄4” Plain Finish USS Flat Washer
Part
Connector
41
42
43
44
45
46
CL311019
DA6153006
CM26006
CM33006
CM28006
1
1
8
1
2
1
Pulley, 10 Groove
3
Common Repl.
⁄8” - 24 x 1” Grade S Plain Finish
Connector (Body 40) - limit switch
Terminal, Female - limit switch
Connector (M-1) - motor
Terminal, Female - motor
#10 -32 x 3⁄32” LG.
Part
Hex Cap Screw
3
19
Common Repl.
Part
CL54108
5
⁄8” Plain Finish Medium Split
Lock Washer
20
21
22
2
1
2
Washer, Thrust
Bearing
Common Repl.
CL656108
Part
1
Common Repl.
⁄2” - 30 x 3” Grade 5 Plain Finish
47
48
CU675108
2
1
Washer
CAP
Part
Hex Cap Screw
1
Common Repl.
∗
23
24
Common Repl.
Part
CU541950W
4
1
⁄2” Belleville Washer
Part
Sprocket Assembly w/ Bearings
∗
These items come with bearings installed.
15
Figure 7
Handle and Control Circuit Assembly – HC12
7, 8
3, 4
14
1
16
19
15
18
10
9
6
5
11
6
17
12
15
13
HC12 Contents
Item # Part #
# Req’d
Description
1
2
3
4
5
CJ458885
1
1
1
2
1
3
Locknut
CM178647SR
CM32006
Plug Assembly
Receptacle, Power Cord
Pin, Cord Receptacle
Pendant Station Assm
#6 -32 X 3⁄8” LG. Button Hd.
2
CM25061
PO5C
6
Common Repl.
Cap
Part
Screw
7
8
DA6152006
CM27061
LK15
1
8
1
1
1
1
4
Receptacle, Pendant
Pin, Receptacle
Decal, Kit
Wiring Diagram
for BMK3 Switch
9
10
11
12
13
LK15
Decal, Kit
EC2006
H905
Circuit Board
Handle
Faceplate
Handle Assembly
1
Common Repl.
Part
⁄
2” - 13 x 7⁄8” Alloy Plain Finish
Socket Head Cap Screw
Black Wire from
Power Plug
1
2
3
14
15
16
DA7046900
F1550
1
1
1
Wire, Jumper
Grip, Cord
Black Wire
Common Repl.
Part
#10 Hi-Collar Helical Spring
Lock Washer
to Circuit Board
White Wire
1
17
Common Repl.
Part
4
⁄2” Plain Finish High Collar Lock
Washer
18
19
CB25
RA19
1
1
Switch
Note: Numbers molded
onto switch by the terminal
verify these before
Braking Resistor
Item 3 is packed with item 4 loose.
Item 7 is packed with item 8 loose.
attaching wires
Instructions provided for assembling loose connectors.
DA 7070900 Limit Switch Jumper (not shown) (for older units)
16
Wiring Schematic
ZERO STOP SWITCH
BEND LIMIT SWITCH
RETURN LIMIT SWITCH
Typical Switch Contacts
COMMON
BLACK
GREEN
WHITE
RED
(OPEN)
(OPEN)
BLUE
(OPEN)
ORANGE
NORMALLY OPEN
BLOCK MOUNTING
NORMALLY CLOSED
NOTE: 2-LONG STUDS FOR COVER MOUNTING ONLY
BOTTOM OF MOTOR
ORANGE GREEN
WHITE
AZ
(42)
BLACK
(41)
YELLOW
(43)
RED
BLUE
(44)
(45)
(46)
GREY
YELLOW
CONNECTOR TO CIRUIT BOARD
(48)
(47)
GREY
POWER CORD
FEMALE CONNECTOR
RED
BLACK
WHITE
BLACK
MALE CONNECTOR
RED
BLACK
BMK3 SWITCH
CIRCUIT BOARD
BLACK
BLACK
WHITE
P5
P7
P8
P6
WHITE
WHITE
FEMALE CONNECTOR
MALE CONNECTOR
17
18
9.0 MAINTENANCE
A troubleshooting aid exists on the printed circuit board mounted to the inside of the operating handle. A white L.E.D. will flash
once every two seconds after power up. The L.E.D. indicates all systems functional. See Figure 13.
Error codes consist of different light patterns.
1. Blink twice, pause, blink twice = the motor is over heated.
2. Blink 3 times, short pause, blink three times, long pause = limit switch has failed.
3. Blinks 4 times, short pause, blinks four times, long pause = pendant control malfunction.
In addition the L.E.D. will be steady on if the bend or return button is being pressed.
White L.E.D.
Figure 13. L.E.D. Location
19
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