Lincoln Electric IM579 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 Safety Depends on You Invertec Power WavetmFumes and Gases can be dangerous SafetyElectric Shock can kill ARC Rays can burnWelding Sparks can cause fire or explosion Cylinder may explode if damagedFor Electrically pow- ered equipment For Engine powered equipment Electric and Magnetic FieldsMay be dangerous Précautions DE Sûreté Please Examine Carton and Equipment For Damage Immediately Thank YouTable of Contents Installation Technical Specifications Power WavePulse Pulse and Background Current Range Voltage Range Select Suitable Location Safety PrecautionsHigh Frequency Precautions Input ConnectionsGround Connections Input Voltage Reconnect ProcedureInput Power Connections Input Fuse and Supply Wire ConsiderationsWater Cooler Connections Wire Feeder ConnectionsOutput Connections Work and Electrode Cable ConnectionsFumes and Gases can be Safety InstructionsOperation Operating InstructionsSave process information if desired Select your process informationRecommended Processes Design Features and AdvantagesOperational Features and Controls Synergic WeldingCase 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 Memory Location # is Empty 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 OptionalRecall from Memory KEY Memory Location Numbers Limits Overlay OptionalOperation Figure B.9 Setup Overlay Setup OverlayNegative Polarity Voltage Sensing Wire Feeder Setup DescriptionPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsPositive Voltage Sensing Polarity STICK/TIG Procedures Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Pulse ProceduresExplanation of Table B.3 Pulse processes Pulse WeldingOverload Protection Thermal ProtectionOver Current Protection Guns and Cables AccessoriesOPTIONS/ACCESSORIES Wire Feeder SetupWater Cooler Usage Maintenance Routine and Periodic MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Locate the #9 and #12 terminals, identified by Discharge labels, on each of the four SwitchPreventive Maintenance Figure D.4 General Component Locations HOW to USE Troubleshooting Guide TroubleshootingTroubleshooting 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 Wiring Diagram Wiring DiagramsHow To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Precaucion Aviso DE Limited Warranty
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