MAINTENANCE | ||
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SAFETY PRECAUTIONS
WARNING
Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrode with skin or wet clothing.
•Insulate yourself from work and ground
•Always wear dry insulating gloves.
See additional warning information throughout this operator’s manual and the Engine manual as well.
REPLACING OR REVERSING DRIVE ROLLS (See
Figure D.1).
Loosen idle roll tension screw (Item 1) to release pres- sure between idle roll and drive rolls.
Remove hex head screw (Item 2) with a 1/2" wrench and remove the drive roll clamping collar (Item 3).
Remove drive rolls from shaft.
Wipe the drive roll surfaces clean. Then install new drive rolls. If reversing drive rolls, turn drive rolls over so unworn teeth face each other.
Replace clamping collar and hex head screw.
Tighten the idle roll tension screw until it bottoms and then back it out two complete turns. If feeding prob- lems persist, do not increase the tension. check for other issues such as the wire spool binding or a dirty or damaged gun cable
REMOVING IDLE ROLL ASSEMBLY
Remove the idle roll tension screw (Item 1), tension spring retainer (Item 4), and tension spring (Item 5).
Pivot the idle roll assembly away from the gearbox and lift it off the pivot pin (Item 6).
To
GUN AND CABLE MAINTENANCE
Remove spatter from tip after each ten minutes of arc time or as required.
Replace worn contact tips and thread protectors as required.
Replace worn spring liners in nozzles. The life of the spring can be doubled by rotating it 180°.
Clean cables after using approximately 300 pounds of electrode. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact nozzle tip from the gun. Using an air hose and only partial pressure, gently blow out the cable from the gun end. (Too much pressure at the start will cause the dirt to form a plug.) Flex the cable over its entire length and again blow out the cable. Repeat this pro- cedure until no further dirt comes out.
Figure D.1
Before any gun is disassembled, remove unit from the wire feeder or shut off the power source.
WIRE DRIVE ASSEMBLY MAINTENANCE
Every 500 pound s of electrode, the drive roll section should be inspected and cleaned out if necessary. Do not use a solvent for cleaning the idle roll as it may wash lubricant out of the bearing.
Replace drive rolls as required. Drive rolls should be worn on both sides before replacing. See “A” of this section.
Check the motor brushes every six months. Replace if they are less than 1/4" long.
Every year examine the gear box and paint the gear teeth with