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D-8
Routine Maintenance of Wire Feed
Unit
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• When inching with gun trigger, electrode
and drive mechanism are "hot" to work
and ground.
• Turn OFF welding power source before
installing or changing drive roll and/or
guide tubes.
• Welding power source must be connected
to system ground per the National
Electrical Code or any applicable local
codes.
• Only qualified personnel should do main-
tenance or troubleshooting work.
Observe all additional Safety Guidelines detailed
throughout this manual.
Drive Rolls and Guide Tubes
After feeding every coil of wire, inspect the drive roll
section. Clean it as necessary. Do not use a solvent
for cleaning the idle roll because it may wash the lubri-
cant out of the bearing. The driver roll and guide tubes
are stamped with the wire sizes they will feed. If a wire
size other than that stamped on the roll(s) is to be
used, the roll(s) and guide tubes must be changed.
The drive rolls for .045" (1.2mm) and .052" (1.3mm)
cored electrode and 1/16" (1.6mm), .068 (1.7mm),
5/64" (2.0mm), and 3/32" (2.4mm) electrode have a
double set of teeth so they can be reversed for addi-
tional life. Between the two knurled rolls (except 1/16"
(1.6mm)) and smaller roll(s) is a shim washer which
limits the damage to the electrode if wire feeding prob-
lems occur. Drive rolls for .023" (0.6mm) through .052"
(1.3mm) solid electrodes have no teeth.
See section on Wire Feed Drive Roll and Guide Tube
Kits for roll changing instructions.
ACCESSORIES
Wire Reel Mounting - 50 (22.7kg) and 60lb
(27.2kg) Coils
To prolong the life of the reel shaft, periodically coat it
with a thin layer of grease.
No maintenance of the two-position adjustable brake is
needed. If the brake shoe wears through to the metal,
replace the brake assembly.
Wire Reel Mounting - Readi-Reels and
10 through 30lb (4.5-14kg) Spools
No routine maintenance required. Do not lubricate 2"
(51mm) spindle.
Avoiding Wire Feeding Problems
Wire feeding problems can be avoided by observing
the following gun handling procedures:
a) Do not kink or pull cable around sharp corners.
b) Keep the electrode cable as straight as possible
when welding or loading electrode through cable.
c) Do not allow dolly wheels or trucks to run over
cables.
d) Keep cable clean by following maintenance instruc-
tions.
e) Use only clean, rust-free electrode. The Lincoln
electrodes have proper surface lubrication.
f) Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or deformed.
g) Do not use excessive wire spindle brake settings.
Periodic Maintenance of Wire Drive Unit
Wire Drive Motor and Gearbox
Every year inspect the gearbox and coat the gear teeth
with a moly-disulfide filled grease. Do not use graphite
grease.
Every six months check the motor brushes. Replace
them if they are less than 1/4" long.
POWER WAVE 450
D-8
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Troubleshooting
