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manual abstract
4 3 6 1 Replace tip if opening is 2 Lightly tighten electrode using electrode wrench (15-20 in.lb (1.7-2.3 Nm). 7 Turn Off power source before checking torch parts. Overtightening will strip threads. Do not overtighten retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts. New Worn 5 *Pit Depth Electrode Wrench deformed or 50% oversized. Turn Off power source. 1 Shield Cup Remove shield cup. Check cup for cracks, and replace if necessary. 2 O-Ring Check O-ring for cracks or worn spots and replace, if necessary. 3 Tip 4 Opening Remove tip. Check tip, and replace if open ing is deformed or 50% oversize. If inside of tip is not clean and bright, clean with steel wool. Be sure to remove any pieces of steel wool afterwards. 5 Electrode Check electrode. If center has a pit more than a 1/16 in. (2 mm) deep, remove and replace electrode. Ref. 804 851-A 6 Swirl Ring Remove swirl ring. Check ring, and replace if side holes are plugged. Carefully reassemble parts in reverse order. 7 Stand-off Guide Placing the stand-off guide on the end of the torch provides an optional method of maintaining a 1/16 in. (1.6 mm) gap between tip and workpiece. OM-244 013 Page 28 A complete Parts List is available at OM-244 013 Page 29 6-6. Torch And Work Cable Connections ! Turn power Off, and disconnect input power plug from receptacle. Check to see that all diagnostic LED’s have stopped flashing before removing wrapper from unit. If torch or work cable needs to be removed or replaced, proceed as follows: 1 Power Source Remove wrapper from unit. Torch Connections Remove existing torch cable from unit. 2 Strain Relief 3 Torch Cable Insert strain relief on end of cable through front panel opening. Slide strain relief nut onto torch cable, but do not tighten. 4 Air Line Connector Insert air line into solenoid fitting. 5 Plug PLG4/Receptacle RC4 Connect PLG4 from torch to receptacle RC4 on end of wiring harness connected to circuit board PC1. Route torch white and red leads and work black lead through sleeving the same way as the unit was originally. 6 Ring Terminal And TORCH WHITE Terminal Connect ring terminal on end of torch white lead to TORCH WHITE terminal. 7 Ring Terminal And TORCH RED Terminal Connect ring terminal on end of torch red lead to TORCH RED terminal. Tighten strain relief screw. Work Cable Connections Remove existing work cable from unit. 8 Strain Relief Loosen strain relief screw. Be sure to allow some work cable slack inside the unit. Insert strain relief on end of cable through front panel opening. Slide strain relief nut onto work cable and secure strain relief to front panel. 9 Work Lead Ring Terminal And WORK BLACK Terminal Connect ring terminal on end of work clamp lead to terminal labeled WORK BLACK. Route lead along torch lead bundle. Reinstall wrapper. Tools Needed: Ref. 804 887-A / 244 409-A / Ref. 244 405-A 3/8 in. 1 2 5 6 7 8 2 7 9 3 4 5 6 . A complete Parts List is available at 6-7. Troubleshooting Power Source Trouble Remedy No pilot arc; difficulty in establishing an arc. Clean or replace worn consumables as necessary (see torch Owner’s Manual). Check for damaged torch or torch cable (see torch Owner’s Manual). No cutting output; Power light off; status lights off; fan motor FM does not run. Place Power switch in On position. Place line disconnect device in On position (see Section 4-11). Check line fuse(s) and replace if needed or reset circuit breakers (see Section 4-11). Pilot arc working; no cutting output; Power light on; status lights off; fan motor running. Be sure work clamp is connected. Clean or replace worn consumables as necessary (see torch Owner’s Manual). No gas/air flow; Power light on; status lights off; fan motor running. Have Factory Authorized Service Agent check for proper torch connections. Check operation of gas valve AS1, and check gas/air system for leaks. Check filter element (see Section 6-2). Pressure status light On. Check for sufficient gas/air supply pressure (see Section 4-1). Check for dirty air filter and replace, if necessary (see manufacturer’s instructions). Check air lines for leaks. Have Factory Authorized Service Agent check pressure switch and control board. Cup status light On. Check torch shield cup (see Section 6-4). Reset power switch. Have Factory Authorized Service Agent check torch. Temperature status light On. Unit overheating. Allow fan to run; the Trouble light goes out when the unit has cooled. Have Factory Authorized Service Agent check control board. Status lights not working. Have Factory Authorized Service Agent check unit. Power light flashing, status lights off. Reset power switch. Have qualified technician check in...
Other models in this manual:Welding Systems - AIRFORCE 700I (1.38 mb)