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7.4
Liner
Removal,
Instructions for REDI-MIG Torch
Note: The variation in cable lengths prevents the inter-
changeability of liners between guns. Once a liner has been
cut for a particular gun, it should not be installed in another
gun unless it can meet the liner cutoff length requirement.
1.
Remove the gas nozzle and nozzle insulator, (if used), to
locate the set screw in the gas diffuser which is used to hold
the old liner in place. Loosen the set screw with an Allen
key.
2.
Remove the gas diffuser from the gun tube.
3.
Lay the gun and cable out straight on a flat surface. Loosen
the liner nut cap located in the brass connector at the
feeder end of the cable and pull the liner out of the cable.
4.
Insert a new untrimmed liner into the connector end of the
cable.
5.
Fully seat the liner bushing into the Euro connector. Tighten
the liner nut cap on the brass cable connector. The gas
diffuser, at this time, should not be installed onto the end of
the gun tube.
6.
With the gas diffuser still removed from the gun tube, be
sure the cable is straight, and then trim the liner to length.
Remove any burrs from the end of the liner.
7.
Screw the gas diffuser onto the end of the gun tube and
securely tighten. Be sure the gas diffuser is correct for the
liner being used.
8.
Tighten the set screw in the side of the gas diffuser against
the cable liner using an Allen key. Do not overtighten.
Procedure for Changing PC Boards
Before replacing a PC board suspected of being defective,
visually inspect the PC board in question for any visible damage
to any of its components and conductors on the back of the board.
1.
If there is no visible damage to the PC board, install a new
one and see if this remedies the problem. If the problem is
remedied, reinstall the original PC board to see if the
problem still exists. If the problem no longer exists with the
old PC board:
a) Check the PC board harness connector pins for
corrosion, contamination, or looseness.
b) Check leads in the plug harness for loose or intermittent
connection.
2.
If PC board is visibly damaged, before possibly subjecting
the new PC board to the same cause of failure, check for
possible shorts, opens or grounds caused by:
a) Frayed or pinched lead insulation.
b) Poor lead termination, such as a poor contact or a short
to an adjacent connection or surface.
c) Shorted or open motor leads, or other external leads.
d) Foreign matter or interference behind the PC board.
3.
If PC board is visibly damaged, inspect for cause, then
remedy before installing a replacement PC board.
Procedure for Changing Settings for
Motor Acceleration
Motor Acceleration needs to be altered from factory setting
because of the welding procedure being used, locate the PCB in
the power source.
On the PC board there is a trimmer labelled 'Rampa', this trimmer
controls the acceleration rate of the drive motor from stationary to
the set wire feed speed. Maximum acceleration when fully
counter-clockwise to minimum acceleration when fully clockwise.
This is particularly important when welding aluminium wire. The
factory setting is fully clockwise.
Page 10
Installation
and
Trimming
REDI-MIG 4D Remote
Section 8 - Ground Test Procedure
WARNING
This procedure is only suitable for applications using DC
mega tester up to 500V.
Note: This procedure is for 'machines as built' many modifications
could have taken place over the life of a machine, so details of this
procedure may need to be adjusted to suit these modifications.
For prompt service contact your local authorised Lincoln
Field Service Shop.
The insulation resistance values listed below are from
Australian Standard AS1966-1.
1.
Disconnect input cable (control and electrode) from welding
power source. Remove gun from wire feeder.
2.
Remove roof panel.
3.
Disconnect the PCB Plug and insert a 20 way shorting plug
into the harness.
4.
Connect Pins A (42), B (4) and C (41) in the Amphenol
together, this connection forms the 'control line' group.
5.
'Control line' Group Test: Connect one lead of the mega
tester to the frame of the machine and the other lead to the
'control line' group. Apply the test. (Min. resistance 1MΩ)
6.
Welding Circuit Test: Connect one lead of the mega tester
to the frame of the machine and the other lead to the
electrode lead. Apply the test. (Min. resistance 1MΩ)
7.
Welding Circuit to 'Control Line' Group Test: Connect one
lead of the mega tester to the electrode lead and the other
lead to the 'control line' group. Apply the test. (Min.
resistance 1MΩ)
8.
Remove all jumpers and reconnect all leads.
9.
Refit the roof panel.
IMA 600A
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