Lincoln Electric IM10024 manual Wire Feed Mechanism, Gear Ratio Conversion Kits See

A-8 INSTALLATION A-8

WIRE FEED MECHANISM

All MAXsa™ Wire Drive units are shipped with 142:1 ratio gears. Conversion kits are included to change to either 95:1 or 57:1 ratio depending on wire size to be used.

As shipped, the drive mechanism parts are designed to feed 3/32 through 7/32(2.4mm - 6.0mm) wire. Other wire sizes will require different drive rolls and guide tubes. See table A.1.

The Idle Roll pressure will need to be adjusted for the wire being used. The indicator shows two settings -

.035 - 3/32” (0.9 - 2.4mm)

.120.- 7/32” (3.0 - 6.0mm)

The tension adjustment is to be made after loading the wire into the drive rolls.

Lower tension may need to be needed to pre- NOTE: vent crushing of some cored wires or softer

alloy solid wires.

GEAR RATIO CONVERSION KITS (See

instruction sheet included with the conversion kit for graphic illustration.)

1.Remove the 2 hex head screws and the 2 slot head screws holding the Motor to the Wire Drive Gearbox assembly.

2.Remove existing Adapter Plate and Motor Assembly.

3.Take the two long screws removed in step 1 and screw one into each of the tapped holes located on the face of fiber input helical gear. Insert the screws through the full thickness of the gear, and using a screwdriver wedged between the screws to prevent rotation, remove the hex nut that holds the gear to the shaft. Remove plain washer.

4.Pull the gear from the shaft using the screws as a pulling device.

5.Be certain woodruff key is properly located on the shaft. Screw the adapter plate and motor assembly mounting screws into the new fiber input helical gear from the stenciled side and place the gear on the shaft. Replace plain washer, tighten the hex nut, and remove the adapter plate and motor assembly mounting screws from the gear.

6.Support the pinion properly and, with the proper size punch, drive the roll pin that holds the pinion out of the shaft. Pull the pinion off. Remove the Ring Magnet from the pinion gear and snap it onto the new pinion gear. Before installing the new pin- ion gear with the Ring Magnet onto the motor shaft, ensure that the flat washer is located at the bottom of the shaft. Install the new pinion and replace the roll pin.

7.Cover the teeth of the motor pinion and the input gear with a non-fluid molydisulfide type grease such as Non-Fluid Oil Corporationʼs A-29 Special/MS Lubricant. This grease can be scooped from the cavity of the gear case.

8.Reassemble the motor to the gearbox. Make sure the gears mesh properly and the adapter plate locating bead is in its cavity. Replace and tighten the four screws removed in step 1.

IMPORTANT

See the MAXsa™ 10, or power source manual for instructions on configuring the system for the new gear ratio.

TABLE A.1 - DRIVE ROLL KITS

KP1899 DRIVE ROLL KIT				INCLUDED WITH KIT
Drive Roll			Drive Roll		Incoming	Outgoing
Kit Number	Wire Sizes & Types		Part Number	No. required	Guide	Guide
KP1899-1	3/32-7/32”	Wires	KP1885-1	2	KP2116-2	KP1963-1
KP1899-2	1/16-3/32”	Wires	KP1886-1	2	KP2116-1	KP2097-2
KP1899-3	.035-.052”	Solid Wire	KP1887-1	1	KP1967-1	KP2097-1
KP1899-4	.045-.052”	Cored Wire	KP1892-1	2	KP1967-1	KP2097-1

NOTE: Twinarc drive rolls are included with the ATwinarc kits.

MAXsa™ 22 & 29 WIRE DRIVES