Lincoln Electric IM524-D manual Preventive Maintenance

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D-4

D-4

MAINTENANCE

PREVENTIVE MAINTENANCE

Perform the following preventive maintenance proce- dures at least once every six months. It is good prac- tice to keep a preventive maintenance record; a record tag attached to the machine works best.

1.Remove the hex head screws from the sides and top of the machine. Remove the handle bar and the machine wrap-around cover. Remove the two case sides. There are hex head screws on each side.

2.Perform the input filter capacitor discharge proce- dure described at the beginning of the Maintenance Section.

3.Disconnect the shunt from the negative (-) output terminal. Failure to do this could cause damage to the shunt circuitry.

4.Clean the inside of the machine with a low pres- sure airstream. Be sure to clean the following components thoroughly (Refer to Figure D.4):

•Display, Snubber, and Shunt printed circuit boards

•Power Switch

•Main Transformer

•Auxiliary Transformers

•Input Rectifier

•Heat Sink Fins

•Input Filter Capacitors

•Output Terminals

•Terminal Strip

8.Reconnect the shunt and wire #467 to the nega- tive (-) output terminal. Make sure the connection is tight.

9.Replace and secure the machine covers and han- dle bar.

10.Remove the overlay from the front panel of the machine. Clean the plastic case with a low pres- sure airstream. Wipe the sensors (Fig D.4 Item 8) with a clean, soft cloth. Make sure the sensors are not scratched in the process.

11.Check the back of the overlays. If the bar code (black square(s)) on the back of the overlay is scratched, apply a dull black spray finish to the scratched-off areas only. If a large area of the bar code is scratched off, the machine either will not recognize the overlay or will mistake the overlay for another one.

12.Inspect gun and cables for good condition.

5.Examine the capacitors for leakage or oozing. Replace if needed.

6.Examine the wrap-around and side covers for dents and breakage. Repair them as needed. The covers must be kept in good condition to assure that high voltage parts are protected and that cor- rect spacings are maintained.

7.Remove welding cables and check the electrical ground continuity. Use an ohmmeter to measure the resistance between each output terminal and an unpainted surface of the machine case. The meter reading should be 500,000 ohms or more. If the meter reading is less than 500,000 ohms, check for electrical components that are not prop- erly insulated from the case. Correct component insulation, if needed.

POWER WAVE 450

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Contents For use with machines having Code Numbers Safety Depends on YouSafety Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Thank You Table of Contents Section F Section CSection D Section ETechnical Specifications Power Wave Pulse Pulse and Background Current RangeFrequency Input Connections Safety PrecautionsHigh Frequency Precautions Select Suitable LocationPower Wave Input Power ConnectionsInput Fuse and Supply Wire Considerations Input Voltage Reconnect ProcedureWater Cooler Connections Wire Feeder ConnectionsOutput Connections Work and Electrode Cable ConnectionsOperating Instructions Safety InstructionsSave process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsInstalling AN Overlay Operating OverlaysOverview Overlay Types OverlayName Overlay ID Number = PULSE, GMAW, FCAW, and STICK/TIG Process Selection OverlayOperation Then Figure B.5 Weld from Memory Overlay Weld from Memory OverlayFigure B.6 Weld from MEMORY, Dual Procedure Overlay Weld from MEMORY, Dual Procedure OverlayOperation Position Procedure Dual Wire FEEDERS, Dual Procedure Overlay OptionalLimits Overlay Optional Recall from Memory KEY Memory Location NumbersSET Limit KEY Limit UP / Down Keys Operation Figure B.9 Setup Overlay Setup Overlay+/- Polarity KEY Wire Feeder Setup DescriptionPositive Voltage Sensing Polarity Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Pulse ProceduresGmaw Stick Table B.3 Adjustble ParametersGmaw FcawOverload Protection Pulse WeldingGuns and Cables OPTIONS/ACCESSORIESWire Feeder Setup Table C.1 Recommended Guns for USE With Power WavePriming the Cooler Recommended CoolantsInput Filter Capacitor DIS Charge Procedure Routine and Periodic MaintenanceFigure D.1 Resistor Locations Discharge labels, on each of the four Switch Locate the #9 and #12 terminals, identified byConnected Preventive Maintenance Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool UsageG3503- Cooler Service G3503- Cooler Periodic MaintenanceFigure D.4 General Component Locations Perform External Recommend HOW to USE Troubleshooting GuideLocate Problem Symptom Consult Local Authorized Field Service FacilityTroubleshooting 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 $700.00 Basic CoursePrecaucion Aviso DE
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