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5- 1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions will determine the
frequency
and
type of maintenance.
Inspect equipment
as
follows:
1.
Make
sure
welding
power
source
is shutdown.
2.
Inspect
gun
for
broken
areas,
cracks and
loose parts:
tighten,
repair,
and
replace
as
required.
3.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate around the nozzle orifice. Use
a
hardwood
stick,
never
a
metal tool.
4.
Repair
or
replace,
as
required,
all hose and
cable;
give
particular
attention
to
frayed
and cracked insulation and
areas
where it
enters
equipment.
5.
Remove
grease
and
grime
from components;
moisture
from electrical parts and cable.
6.
Blow
out
the gun wire
guide
liner with
compressed
air
when
changing
wire. This will
remove
any
metal
chips
and
dirt that may have
accumulated.
5 -2.
CLEANING OF DRIVE ROLL BEARINGS
Occassionally
it will become
necessary
to
clean and oil the
oilite
bearings
which
are
pressed
into the four drive rolls. This
cleaning operation
should be
performed
whenever the oilite
bearings
appear
dirty
and
grimy.
To clean and oil these
bearings
it will be
necessary
to
first
remove
the
four
drive
roll
gears.
(See
Section
2-10 for
removal and installation
instructions.)
Once
removed,
use a
clean rag
to
wipe
the
bearings
clean.
Apply
a
light
coat
of oil
to
the
bearings,
and install the
bearings
back
onto
the drive
roll shafts.
5- 3. FUSE
(Figure
2-4)
The
control/feeder
is
protected
from
damage
due
to
an
internal
short
or
excessive overload
by
a
fuse. Fuse Fl
is
located
on
the
rear
panel
of the control. If Fl should open.
the
control/feeder
would be
completely inoperative.
Hazardous
voltages
are
present
on
the
internal
cir
cuitry
of
the
control/feeder
as
long
as
power
is
connected
to
the
unit.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside of the
unit.
Troubleshooting
of internal
circuitry
should be
performed by qualified personnel only.
The
following
chart
is
designed
to
diagnose
and
provide
remedies for
some
of the troubles that
may
develop
in this
control/feeder.
It
is
assumed
that
proper
installation
has
been
made,
according
to
Section
2
of
this
manual,
and
that
the
control/feeder
has
been
functioning properly
until
this
trouble
developed.
Use this chart
in
conjunction
with the circuit
diagram
while
performing troubleshooting procedures.
If the trouble is
not
remedied
after
performing
these
procedures,
the
nearest
Factory
Authorized Service Station should
be contacted. In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations should be
strictly
followed..
SECTION 5- MAINTENANCE
-
~
SECTION
6
-
TROUBLESHOOTING
TROUBLE
PROBABLE CAUSE
REMEDY
Depressing
gun
switch
will
not
energize
control/feeder.
Electrode
wire
is
not
energized
and
shielding
gas does
not
flow.
POWER switch in
wrong
position
or
defective.
Place switch
to
ON
position.
Circuit breaker
(CB1 ) tripped.
Replace
defective POWER switch.
Manually
reset
circuit breaker
by
depressing
the
button
on
the
front
panel
of
the
control/
feeder labeled RESET.
Plug
from gun switch is
not
secure
in Switch
Control
receptacle (RC2)
on
control/feeder.
Insert
plug
fully
into
Switch Control
receptacle
(RC2)
and
rotate
plug
1/2
turn
clockwise.
115
volts
ac
input
plug
is
not
secure
in
receptacle (RC7)
and/or
input
line,
Insert
plug fully
into 116
vac
receptacle (RC7)
and
rotate
plug
1/2
turn
clockwise,
check
plug
at
input
line.
115 volts
input
fuse
(Fl)
open.
*Replace
fuse
(Fl).
Lead(s)
31
or
33
on
the
rear
of the Switch
Control
receptacle
is loose.
Remove
control/feeder
cover
and check lead 31
& 33 connections
on
the
rear
of the
receptacle.
Coil
of
plug-in
relay (CR1)
defective.
Replace relay (CR1).
Wire
feeds, shielding
gas
flows,
but
electrode
wire
is
not
energized.
~
115
vac
Contactor Control
plug
is
not
secure
in
contactor
receptacle
on
welding
power
source
and/or control/feeder.
Insert
plug
fully
into
receptacle
and
rotate
plug
1/2
turn
clockwise
(check
both
ends).
Contactor
Control
cable
leads
not
secure
on
contactor
plug
terminals.
Secure leads
to
plug
terminals.
Defect in
welding
power
source.
See
troubleshooting
section
in
welding
power
source
instruction manual.
Wire feeds
erratically.
Pressure
on
drive rolls is insufficient.
Rotate
pressure
adjustment wing
nuts
clockwise
in
1/4
turn
increments until wire
slippage
stops.
Drive roll is
too
large
for wire size
being
used.
Change
to
proper
size drive roll. See Section
2-10.
Worn drive roll.
Replace
drive roll. See Section 2-10.
Dirt in drive roll.
Clean drive roll
as
instructed
in
Section 5-2.
*If it becomes necessary
to
replace
any
fuse in the
control/feeder,
ensure
that
a
fuse of the proper size is used.
Page
6
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