40
SECTION 5 MAINTENANCE
If it should become necessary to re-
place this or any other fuse in the weld-
ing machine, ensure that the proper size
fuse is used as a replacement.
To avoid shock, do NOT touch electrode
wire or parts in contact with it, or
uninsulated cable or connections.
5.2.1.3 TRANSFORMER
Occasional blowing out of the dust and dirt from around the transformer is
recommended. This should be done periodically depending upon the location
of the unit and the amount of dust and dirt in the atmosphere. The welding
machine case cover should be removed and a clean, dry air stream should be
used for this cleaning operation.
5.2.1.4 24 VOLTS WIRE FEEDER AND CONTROL CIRCUITS
The 24-volts circuit is protected by a 10 amp fuse in a panel mounted
fuseholder, accessible from the wire feeder compartment. Failure of this fuse
will shut off the contactor, shielding gas and wire feeder.
5.2.1.5 OVER-TEMPERATURE PROTECTION
The machine is equipped with a thermostat. On continued high current
application, if the thermostat reaches an abnormally high temperature, it will
deenergize the contactor. This thermostat will reset itself automatically after the
transformer windings have cooled to a safe level. While deenergized, neither
the contactor, shielding gas nor wire feeder can be operated.
5.2.2 WIRE FEEDER
When soft wire is fed, the drive rolls may pick up metal from the wire surface.
Accumulation on the rolls may score the wire with resulting unwanted friction
and improper feeding.
Inspect the rolls regularly and clean them with a fine-wire power brush. Avoid
roughening, or removing the hardness of groove surfaces in grooved rolls. Any
roughening may score the wire, just as the accumulation being removed may
do.
5.3 TROUBLESHOOTING
If welding equipment doesn’t work right despite compliance with checklist
inspect as follows:
A. With all power controls ON and other operating controls at required settings,
visually check all power cables and connections for evidence of overheating
or sparking.
B. Check all gas (and water) hoses and connections, flowmeters, and regula-
tors for possible sources of leakage, breakdown or intermittent failure.
C. Isolate trouble to one part of the welding installation: primary power supply,
power source, Feeder or wire guide train (casing, drive rolls, liners and
contact tip). If this inspection indicates trouble in the Feeder, use Trouble-
shooting Guide, Table 5.1 and schematic diagram (Figure 5.1).
5.3.1 IF MOTOR DOES NOT RUN:
A. Check for blown fuse. If blown, check that motor is not binding before
replacing fuse.
B. Check for continuity across speed potentiometer (POT) and wiper
contact. Voltage from center tap to MIN end should vary from 0 to 5.4
VDC as potentiometer is rotated clockwise.
C. Check wiring for continuity. Then turn power ON and check for 30 Vdc
across input terminals 8 and 9 on the feeder printed circuit board
connector (PL1).
D. Press torch trigger, and check for voltage across motor (Pins 4 to 7) of
speed control board; should vary from 1 to 24 VDC as speed control
potentiometer is rotated clockwise.
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