Lincoln Electric IM542-D manual G3503- Installation or SER Vice Tool Usage

Page 54

E-5

E-5

MAINTENANCE

RECOMMENDED TOOLS FOR INSTAL- LATION OR SERVICE OF COOLER:

•absorbent towels

•alcohol wipe

•3 mm allen wrench (G3503 only)

•socket wrench

•4 inch long minimum socket extension

•1/4, 5/16, and 3/8 hex standard depth sockets

•5/32 allen socket

•medium blade slotted screwdriver

•large blade slotted screwdriver, 8 inches long minimum

•two 7/16 open or box end wrenches

•one 7/8 open or box end wrench

•needlenose pliers

•two 10 inch long adjustable wrenches

•wire cutter

•molex pin removal tools

•tape measure

•small mechanic’s mirror

•flashlight

•dental pick

•digital multimeter (DMM)

REMOVING AND INSTALLING THE G3503-[ ]

COOLER

1.Preparation:

•Always switch off the Power Wave machine power.

•Always disconnect the Power Wave machine from service input power.

2.Remove cooler assembly G3503-[ ]:

a.remove gas cylinder(s) from tray.

b.remove cooler access panel.

c.Remove both fasteners from base that hold cool- er in place. Remove ground lead, if present. Carefully pull cooler assembly rearward, until cooler’s Molex connectors are visible.

d.disconnect cooler’s connectors from the P3 and P4 harnesses. Continue pulling the cooler out of the Power Wave.

3.If necessary, perform periodic maintenance or ser- vice on the cooler.

4.Reinstall cooler by reversing tasks in step 2. Be sure to reattach ground lead, if previously removed.

G3503-[ ] INSTALLATION OR SER-

VICE TOOL USAGE

Fastener Usage

Qty.

Tool

Shroud to cooler base

4

all use 5/16 hex screw and 3/8 hex

Quick Disconnect (QD) bracket

2

nut. Relay may require large blade

Heat exchanger to cooler base

2

slotted screwdriver 8 in. long min.

Relay to cooler base

2

 

 

Screw to

4

3 mm allen wrench (G3503 only)

fasten reservoir to cooler base

 

5/16 Hex Socket (G3503-1 only)

Hose Clamp

10

1/4 hex or medium slotted screwdriver

 

 

 

 

Fan set screw

1

5/32 allen socket with wrench and 4

 

 

in. min. extension

Pump carbonator clamp screw

1

5/16 hex socket with ratchet wrench

Motor mounting bolts

4

two 7/16 open or box end wrenches

 

 

 

 

Motor access door

2

1/4 hex socket with wrench

 

 

 

 

Motor harness ground at motor

1

1/4 hex socket with wrench

terminals

2

needlenose pliers

 

relay terminals 1 and 2

2

large blade slotted screwdriver 8 in.

 

 

minimum long.

relay terminals 3 and 4

2

medium slotted screwdriver

5.If necessary, fill cooler with selected coolant to spec- ified level (see Fig. 1).

6.Attach desired water-cooled accessory (gun and wire feeder or TIG torch) to cooler’s QDs.

7.Reconnect service input power to the Power Wave:

•verify that the reconnect panel setting and lead placement match the service voltage.

8.Prime the cooler:

a.Install the Set-up overlay.

b.Keep accessories’ hose lengths horizontal, either coiled or straight, and no higher than 4 feet of the specified coolant level (Fig. 1).

c.Switch on the Power Wave machine.

d.Press the "WATER COOLER ENABLE" button so that the "WATER COOLER ENABLED" light is illuminated .

e.Press the "PRIME WATER COOLER" button until the "WATER COOLER PRESSURE" light is steadily illuminated.

9.Check coolant level. Add more if required.

All plumbing components

N/R two 10 inch adjustable wrenches

POWER WAVE 450

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Contents Safety Depends on You For use with machines having Code NumbersSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Vii Section CViii Section DSection G Section ESection F SeriesPower Wave InstallationTechnical Specifications Power Wave AwgiecSelect Suitable Location Safety PrecautionsHigh Frequency Precautions Input ConnectionsInput Voltage Reconnect Procedure Input Power ConnectionsInput Fuse and Supply Wire Considerations Ground ConnectionsWork and Electrode Cable Connections Wire Feeder ConnectionsOutput Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Safety Instructions OperationOperating Instructions Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsInstalling AN Overlay Operating OverlaysOverview Overlay Types OverlayName PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Overlay ID Number =Operation Then Robotic Interface Weld from MEMORY, Dual Procedure Overlay Select a Memory LocationOperation Limits Overlay Optional Recall from Memory KEY Memory Location NumbersSET Limit KEY Limit UP / Down Keys Operation Setup Overlay Figure B.7 Setup OverlayPositive Polarity Voltage Sensing Wire Feeder Setup Description+/- Polarity KEY Table B.1 Positive Voltage Sensing OptionsPulse Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Wave ControlTable B.3 Adjustble Parameters GmawFcaw Thermal Protection Pulse WeldingOverload Protection Current ProtectionRobot Signal Descriptions Robotic InterfaceInterface Description Wire Fault Touch Sense SignalGAS Fault Water FaultWire Stick Detect Power Wave CircuitsDual Procedure Switch COM- Mand Robot Controller Electrical CharacteristicsWater Fault Touch Sense Command ARC DetectGAS Fault Power Fault Dual Procedure Switch CommandWeld Equipment Setup Robot Controller SetupWeld System Setup Touch Sensing SetupArctool Welding Inputs and Outputs Power Wave Interface BoardConnections Miscellaneous ConnectionsRecommended Coolants AccessoriesWater Cooler Usage Priming the CoolerL9777 Wire Feed Unit Dimension Print For the LatestType Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power SourceAluminum Wire Sizes Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Feeding Electrode and Brake Adjustment Requires Installation of 2 51MM K162H Spindle KITWire Loading of 13-14lb 6kg Innershield Coils To Mount a 50-60lb 22.7-27.2kg CoilFeeding Electrode Periodic Maintenance of Wire Drive Unit Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsAvoiding Wire Feeding Problems Wire Drive Motor and GearboxSwitch Requirements Connector for 1/16 5/64 1.6 2.0 mm WireMaintenance Routine and Periodic MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Discharge labels, on each of the four Switch Locate the #9 and #12 terminals, identified byConnected Preventive Maintenance G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure D.4 General Component Locations Troubleshooting HOW to USE Troubleshooting GuideED Tests Troubleshooting Guide Authorized Field Service FacilitySists, contact your local Lincoln Play fans run Check circuit breaker 5-amp Observe Safety Guidelines Controls and Settings Power-up Inspect the overlay bar code Saved in memory are different Check for proper shielding gas Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding Basic CoursePrecaucion Aviso DE
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