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A-9
WIRE FEED MECHANISM
All MAXsa™ Wire Drive units are shipped with 142:1
ratio gears. Gears are included to change to either 95:1
or 57:1 ratio depending on wire size to be used.
As shipped, the drive mechanism parts are designed to
feed 3/32 through 7/32(2.4mm - 6.0mm) wire. Other
wire sizes will require different drive rolls and guide
tubes. See table A.1.
The Idle Roll pressure will need to be adjusted for the
wire being used. The indicator shows two settings -
.035 - 3/32" (0.9 - 2.4mm)
.120.- 7/32" (3.0 - 6.0mm)
The tension adjustment is to be made after loading the
wire into the drive rolls.
NOTE: Lower tension may need to be needed to pre-
vent crushing of some cored wires or softer
alloy solid wires.
GEAR RATIO CONVERSION
(See Figure A.4b)
1. Remove the 2 hex head screws and the 2 slot head
screws holding the Motor to the Wire Drive Gearbox
assembly.
2. Remove existing Adapter Plate and Motor Assembly.
3. Take the two long screws removed in step 1 and
screw one into each of the tapped holes located on
the face of fiber input helical gear. Insert the screws
through the full thickness of the gear, and using a
screwdriver wedged between the screws to prevent
rotation, remove the hex nut that holds the gear to
the shaft. Remove plain washer.
- WIRE DRIVE MOTOR GEAR BOX
DRIVE MOTOR
BRUSH ACCESS
HEX HEAD
SCREW
ADAPTER
PLATE AND
MOTOR
ASSEMBLY
FIRST
CHAMBER
PIPE
PLUG
WIRE DRIVE
GEARBOX
SECOND
CHAMBER
SLOT HEAD
SCREW
INSTALLATION
4. Pull the gear from the shaft using the screws as a
pulling device.
5. Be certain woodruff key is properly located on the
shaft. Screw the adapter plate and motor assembly
mounting screws into the new fiber input helical
gear from the stenciled side and place the gear on
the shaft. Replace plain washer, tighten the hex
nut, and remove the adapter plate and motor
assembly mounting screws from the gear.
6. Support the pinion properly and, with the proper
size punch, drive the roll pin that holds the pinion
out of the shaft. Pull the pinion off. Remove the
Ring Magnet from the pinion gear and snap it onto
the new pinion gear. Before installing the new pin-
ion gear with the Ring Magnet onto the motor shaft,
ensure that the flat washer is located at the bottom
of the shaft. Install the new pinion and replace the
roll pin.
7. Cover the teeth of the motor pinion and the input
gear with a non-fluid molydisulfide type grease such
as Non-Fluid Oil Corporation's A-29 Special/MS
Lubricant. This grease can be scooped from the
cavity of the gear case.
8. Reassemble the motor to the gearbox. Make sure
the gears mesh properly and the adapter plate
locating bead is in its cavity. Replace and tighten
the four screws removed in step 1.
See the MAXsa™ 10, or power source manual for
instructions on configuring the system for the
new gear ratio.
FIGURE A.4b
- CH ANGING THE WIRE FEED GEAR RATIO
HEX NUT (11)
PLAIN WASHER (9)
INPUT
SLOT HEAD
HELICAL
SCREWS
GEAR (12 )
(MOUNTING
WIRE FEED
SCREWS)
GEARBOX
WOODRU FF
KEY (8)
MAXsa™ 29 WIRE DRIVE
IMPORTANT
- DRIVE MOTOR PINION
GEAR REMOVAL
WIRE
DRIVE
MOTOR
SHAFT
ADAPTOR
PLATE
PINION
ROLL PIN
MOUNTING
SCREW
A-9
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