Advertisement
6.5 Liner Removal, Installation and Trimming
Instructions for REDI-MIG 240 MIG Gun
Note: The variation in cable lengths prevents the
interchangeability 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.
°
Drive Rolls for mild steel, stainless steel and aluminium
for solid wires as well as for flux cored wires. See your
nearest Lincoln distributor for details.
°
1.2mm Aluminium Welding Kit complete with 0.9mm,
1.2mm U-groove drive rolls, 0.9-1.2mm Teflon torch
liner, packet of 10 x 1.2mm contact tips, Teflon inlet and
outlet guides (KA1440-4 for REDI-MIG 255 Integrated
and KA1440-5 for REDI-MIG 255 Remote).
WARNING
This procedure is only suitable for applications using DC
mega testers up to 500V.
ELECTRIC SHOCK
can kill
Note: This procedure is for 'machines as built' many
modifications could have taken place over the life of a particular
machine, so details of this procedure may need to be 'adjusted' to
suit these modifications.
For prompt service contact your local Lincoln Field Service Shop.
The insulation resistance values listed below are from Australian
Standard AS1966.1.
If any problems are encountered refer to your nearest authorised
Lincoln Field Service Shop.
1)
Disconnect input cable from power supply.
2)
Disconnect gun assembly and work cable.
3)
Remove the LHS side panel from power source and Wire
Feeder.
Procedure for Replacing 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.
Changing Settings for Motor Acceleration
If Motor Acceleration needs to be altered from factory setting,
because of the welding procedure being used, locate the PCB in
the REDI-MIG 255 Integrated power source of REDI-MIG 4D
Remote Wire Feeder.
Page 20
Section 7 - ACCESSORIES
Section 8 - GROUND TEST PROCEDURE
REDI-MIG 255
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.
°
1.2mm Flux Cored, Gas and Gasless Welding Kit,
complete with 0.9, 1.2mm knurled drive rolls, 0.9-
1.2mm torch liner and packet of 10 x 1.2mm contact
tips (KA1441-4 for REDI-MIG 255 Integrated and
KA1441-5 for REDI-MIG 255 Remote).
°
Innershield (self shielded or gasless wire) Welding Gun
with Euro connect fitting for best results with gasless
wires. (KA1325).
4)
Jumper the two (3) AC terminals and the (+) terminal of the
bridge rectifier (A total of three (3) places).
5)
Jumper the four (4) meter terminals together.
6)
Disconnect the PCB plug and insert a 20 way shorting plug
into the harness.
7)
Switch the 'fine' control rotary switch to position 'a' and
switch the 'course' control toggle switch to position 'A'.
8)
Primary Test: Connect one lead of the mega tester to the
frame of the machine and the other lead to the Active
terminal of the input plug. Apply the test. (Min resistance
1MΩ).
9)
Welding Circuit Test: Connect one lead of the mega tester
to the frame of the machine and the other lead to the (+)ve
output stud. Apply the test. (Min resistance 1MΩ).
10)
Welding Circuit to Primary Test: Connect one lead of the
mega tester to the (+)ve output stud and the other lead to
the Active terminal of the input plug. Apply the test. (Min
resistance 10MΩ).
11)
Transformer Thermostat Test: Connect one lead of the
mega to the frame of the machine and the other lead to No
42 (transformer thermostat). Apply the test.(Min resistance
1MΩ).
12)
Remove all jumpers and reconnect all leads and plugs.
13)
Refit all panel work previously removed.
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. Damaged lead insulation.
b. Poor lead termination, such as a poor contact or a
short to 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.
On the PCB 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.
IMA 598B
Advertisement
