D W E L L C Y L I N D E R P R O B L E M S
SYMPTOM
CORRECT
FUNCTION
INDICATOR
POSSIBLE
PROBLEM
ACTION
Dwell Cylinder does
not retract and
weld stays on.
Initiate, Weld Tim-
er, Feed Reed
Switch, Dwell
S o l e n o i d a n d
Weld Signal Indi-
cators are all on
constantly.
All lights flash in se-
quence.
Weld Timer.
Remove the push-on connector from terminal #4 of the Weld Timer. If the
Dwell Cylinder retracts and the weld turns off replace the Weld Timer.
Dwell Cylinder does
not retract and
weld stays on.
Initiate, Dwell
Solenoid and
Weld Signal
I n d i c a t o r s
are all on con-
stantly.
All lights flash in se-
quence.
Short Cycle
Relay.
In the Trolley, test for voltage (24VAC approx.) at terminals #7 and #8.
If the voltage is present return to the step above. If the voltage is not
present, now check the voltage (24VAC approx.) at terminals #4 to #8
and #1 to #12. If the voltage is present all the time on these terminals
replace the Short Cycle Relay.
Dwell Cylinder does
not retract.
Dwell Solenoid and
Dwell Delay In-
dicators are on
constantly.
Dwell Solenoid In-
dicator goes on
and off with ev-
ery cycle. Stays
on 150ms lon-
ger than Feed
Reed Indicator.
Dwell Timer.
Remove the push-on connector from terminal #4 of the Dwell Timer. If the
Dwell Cylinder retracts replace the Dwell Timer.
Dwell Cylinder does
not retract.
All Indicators are
functioning cor-
rectly.
All lights flash in se-
quence.
(A) Dwell
Solenoid.
(A) Turn the power off. (If the Dwell Cylinder shaft retracts, recheck the
symptom). Now try and lift the Dwell Cylinder shaft up. If the cylinder
shaft cannot be lifted replace the Dwell Solenoid.
(B) Dwell
Cylinder.
(B) If the Dwell Cylinder shaft can be lifted easily check the Dwell Cylinder
and the air lines for air leaks. Turn the air off and then move the cylinder
shaft up and down. If the cylinder shaft moves up and down without any
air resistance the seals in the cylinder are most likely worn. Replace the
Dwell Cylinder. If a slight air resistance is present on the up and down
motion check the Quick Exhaust Valve.
(C) Quick
Exhaust Valve.
(C) The Quick Exhaust Valve is a pneumatic check valve. To check the Quick
Exhaust Valve, dissasemble the valve and inspect the conical shaped
diphragm for any tears. If any damage is noted, replace the Quick Ex-
haust Valve or repair it with a repair kit (part# 17078).
Sluggish movement
of the Welding
Tip.
All Indicators are
functioning cor-
rectly.
All lights flash in se-
quence.
(A) Air
Regulator.
A) Adjust the Air Regulator (80psi).
(B) Air Lines
and Adjust-
able Exhaust
Mufflers.
(B) Check Air Lines for leaks or water. If there is water in the Air Lines,
disconnect and blow out the Air Lines. Remove and clean out the Ad-
justable Exhaust Mufflers. Reconnect the Air Lines and the Adjustable
Exhaust Mufflers.
(C) Dwell
Cylinder.
(C) Turn the power and air off. Check the Dwell Cylinder shaft for binding by
moving the shaft in and out of the cylinder. A slight air resistance should
be present when the shaft is being moved in and out of the cylinder.
(D) Dwell
Solenoid.
(D) If the above procedures check out and the Dwell Cylinder still has slug-
gish movement, the problem maybe the Dwell Solenoid. Remove the Air
Line from air inlet of the solenoid and spray a light oil into the solenoid.
Reconnect the air line and cycle the machine. If the Dwell Cylinder still
has sluggish movement replace the Dwell Solenoid.
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