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Duro Dyne RH Mach III, Owner'S Manual

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Duro Dyne RH Mach III Owner'S Manual Download Page 9

-9-

WIRING DIA

GRAM

 RH - MA

CH III

 

RED

TB

1

RECEIVER BD

H

G

F

D

C

A

E

B

RE

D

RED

WHT

TRA

CK SENSOR

GRN

WHT

RCVR LE

D

BLK RE

D

EMIT

TER LE

D

VIBR

AT

OR BASE

B.C.

RED

9vdc

RED

BL

K

WELD LAMP

PL

UG

VIBRA

TO

R

GRN

GUN

SWIT

CH

C

NO

GUN SWIT

CH

PL

UG

WELD GUN

PO

T

VIBRA

TO

R

RED

220v SINGLE

PHASE POWER

GRN

COMPONENT

MODUL

E

BL

K

YE

L

WHT

SP

ARES

RED

YE

L

SP

ARES

GRN

BL

K

END 

TO

 MIDDLE

LOW OUTPUT

HIGH OUTPUT

END 

TO

 END

BL

K

BL

U

WHT

47k

TIMER

TIMER

SHORT CY

CLE

FIRST PULSE

BL

K

GRN

BL

U

BL

K

BLK

RED

FUNC

TION DISPLA

Y 

VIBRA

TO

R

CIRCUIT BRKR

(2AMP

)

4

3

5

1

12

PIN FEED

WELD

-2

A1

WELD  PO

T

B

A

OUTLE

T

220V

6
7
8
9

10
11

5

4

3

2

1

DWELL

2

3

1

5

4

4

56

78

12

12

10

91

1

14

13

12

8

11

7

43

10

6

9

5

2

1

1

2

5

9

6

10

3

4

7

11

8

12

13

14

4

4

5

1

3

2

WEL

D

DWELL REED

REED SWIT

CH

FIRST PULSE

TB-2

TROLLE

Y

RELA

Y #4

RELA

Y #5

11

91

0

8

7

6

5

4

WELD

-1

SWIT

CH

JUMPER

RED

BL

K

BL

K

RED

SWIT

CH

FEED REED

RED

BL

K

WHT

YE

L

BL

U

WHT

BL

K

RED

16/3 CABLE

18/2 CABLE

TEST

HEAD

SP

ARES

SP

ARES

20/6 CABLE (BL

UE BAND

)

YEL

BL

U

BL

K

BL

K

BL

K

BL

K

WHT

WHT

BL

K

BL

K

BL

U

YE

L

GRN

WHT

RED

BL

K

BL

K

YE

L

WHT

BL

U

BLK/YEL

WHT/VIO

WHT/BRN

BLK/RED

WHT/BLK

WHT/RED

WHT

GRN

BRN

OR

N

VI

O

GR

Y

BL

U

YE

L

WHT/G

RY

WHT/B

LU

WHT/GR

N

WHT/YE

L

WHT

BL

K

GRN

20/20 CABLE

GRN

20/6 CABLE (

WHITE BAND)

WHT

WHT

WHT

BL

U

GRN

YE

L

RED

BL

K

GRN

POWER SW

A3

B4

B5

1A

3B

2A

4B

BLK/YEL

TIMER

SP

ARES

WHT/VIO

BL

K

BRN

1

3

2

5

1

3

2

FEE

D

23

1

JUMPER

BLK/RED

WHT/BRN

WHT/BLK

ORN

WHT/G

RY

BL

U

YE

L

WHT/GRN

WHT/YEL

WHT/B

LU

VI

O

GR

Y

GRN

RED

YEL

WHT/RED

WHT

WELD 

TRANSF OPTION

S

(RED BAND

)

20/6 CABLE

BL

K

RED

GRN

POWER 

PA

CK

WELD TRANSF

RECEPT

FOO

TSWIT

CH

WELD

COPPER

CABLE

BAR

SEE SPECS ABOVE FOR

B.C.

RED

PRESSURE

SWIT

CH

BLU

RED

MAIN POWER

Hi

Lo

INPUT

DIGIT

AL DISPLA

Y

2

14

5

G

ORN

1

2

4

5

BRN

BL

K

TO

 DISPLA

Y

CONNEC

TO

R

5 PI

N

GRN

RE

D

YE

L

82k

BL

K

GUN

SWIT

CH

BL

K

YE

L

BL

U

BLK

SOL

-1

FEED

BL

K

SOL

-2

DWELL

SP

ARES

YE

L

RED

GRN

RECEPT

GUN SWIT

CH

BLK

BL

K

YEL

RH MA

CH-III 

WIRING DIA

GRAM

RED

SUPPL

Y (6GA

)

R

R

VIBRA

TO

R

COIL

WELD 

TRANSF OPTION

WHT

YE

L

RED

RED (8GA

)

BLK (8GA

)

WHT

WHT

RED

R;1k

TB-3

BLK

T5

T10

T9

T11

T1

T2

T3

RELA

Y BR

D

VIB CNTR

L

COMM

H

ML

MH

24v C

OIL

CONT

AC

TO

R

220

v

#2

GRN

RED

BLK

RED

BLU

WHT

YEL

BLU

GRN

WHT

BLK

BLU

BLK

WHT

YE

L

BL

U

RED

BLK

TB-1

11B

12B

12T

11T

RED

RED (8GA

)

RED (8GA

)

SUPPL

Y

POWER

24V

24V

#1

WELD RELA

Y

4/A2

3/A1

1/L1

2/T1

BR

G

N

L

-V

+V

12VDC

WELD RELA

Y

#2

1/L1

2/T1

3/A1

4/A2

1T

2T

3T

4T

5T

6T

7T

8T

9T

10T

10B

9B

8B

7B

6B

5B

4B

3B

2B

1B

GRN

RED

#1

GRN

T1

L1

L2

T2

BL

K

WHT

BL

U

BLK

BL

K

RED

BL

K

RED

BLK

RED (8GA

)

TRANSFORMERS

YEL

BL

U

YE

L

RE

D

YE

L

ORG

YEL

ORG

RED

RED

208

v

240

v

VOL

TA

GE

SWIT

CH

BLK

BLK

VIBRA

TO

R

SENSOR

VIBRA

TO

R

CONSOLE

CONTROL

VIBR

AT

OR

SPEED

CONTROL

(7K

VA/60AMP 

WELD 

TRANSFORMER)

WIRE 

CO

LOR CHAR

T

= BUT

T 

CO

NNEC

TORS

SY

M

CO

LO

R

SY

M

YELL

OW

WHITE

BL

AC

K

GREE

N

RE

D

WHT

GRN

BL

K

YE

L

B.

C.

RED

OR

N

BRN

BL

U

VI

O

GR

Y

CO

LO

R

BL

UE

BROWN

VIOL

ET

ORANGE

GR

AY

SY

M

CO

LO

R

C

H

MH

ML

L

L

WH

T

BLK

RE

D

BL

U

B230-01-26/LA

TEST

: 2-25-16

Summary of Contents for RH Mach III

Page 1: ...OWNER S MANUAL ROLLING HEAD PINSPOTTER R H M a c MACHINERY DIVISION RH MACH III RH MACH III ...

Page 2: ...h product LIMITED WARRANTY Duro Dyne Machinery is manufactured by skilled mechanics utilizing the latest production techniques Each unit has been rigorously tested prior to packaging and shipment in order to ensure trouble free operation Your Duro Dyne machine has a two year warranty against defects in material Any component found to be defective will be repaired or replaced at the manufacturer s ...

Page 3: ...Pack Cover 17284 Trigger Actuator Switch 17278 Steel Track 17395 Lower Ground Bar 17391 Actuator Swival Bolt 17190 Lower Replacement Plates 5 pkg 17376 Lower Mandrel 17191 Upper Weld Tip 17189 Upper Replacement Plates 5 pkg 17192 Lower Weld Tip Transformer Enclosure Triangle Enclosure 44118 Trolley 44119 Trolley Cover 3 ...

Page 4: ... 17269 Feed Cylinder Bracket 17351 Pusher With Pawl 17348 Feed Channel Plate 44088 Flex Link 44095 Track Sensor 17264 Upper Track Side Rails 44086 Clip Pin Release Spring 44085 Clip Pin Release 44084 Locking Knob Catch 18056 Locking Knob 17265 Lower Track Side Rails 39353 Anti Friction Strip 17394 Short Shaft Extension 17203 Fiber Insulator 17352 Upper Tip Retainer 17266 Feed Channel 44013 Feed Ch...

Page 5: ...ck 44122 Trolley Mounting Plate 17276 Upper Bearing 44121 Control Console 44024 Main Power Switch 44027 Knob 44008 Upper Feed Track Casting 44077 Weld Poteniometer 39110 Pin Feed Switch 44029 Head Test Switch 44087 Clip Pin Release Stop 18056 Locking Knob 44034 Weld Lamp 17277 Lower Bearing 44071 Feed Cover 17261 Lower Feed Track Casting 18066 220V Phase Control Located Inside Control Console 4411...

Page 6: ...0 Brake Cylinder 17290 Brake Pad not shown 17236 Dwell Cylinder Bracket 17323 First Pulse Relay 17327 Actuator Receptacle 17240 Dwell Solenoid 17334 Auto Handgun Switch 17239 Feed Solenoid 27213 Flush Mount Camlock 17318 Feed Timer 17319 Dwell Timer 44079 Low Voltage Terminal Strip 17355 Quick Exhaust Valve 17325 Pressure Switch 17302 Weld Timer B Dwell Retract Adj Muffler Up A Feed Adj Muffler C ...

Page 7: ...24 Volt Multi Tap Transformer For Contractor XSFMR 1 44053 Weld Relay 1 44054 Heat Sink 44090 Vibrator Control Relay Board 44052 12 Volt DC Power Supply 44115 High Voltage Terminal Strip 39306 Incoming Voltage Select Switch 44091 24 Volt Multi Tap Low Voltage Control XSFMR 2 44053 Weld Relay 2 7 ...

Page 8: ...switch Receptacle 17377 Air Regulator 44070 Weld Cable Lug Connector 44041 Line Cord 44089 Weld Cable Long 44067 Flexible Wire Mold 44068 Rubber Air Hose 44069 Wire Harness 44101Weld Transformer 44042 Line Cord Strain Relief 44105 Power Pack Tray 8 ...

Page 9: ...N 1 3 2 5 1 3 2 FEED 2 3 1 JUMPER BLK RED WHT BRN WHT BLK ORN WHT GRY BLU YEL WHT GRN WHT YEL WHT BLU VIO GRY GRN RED YEL WHT RED WHT WELD TRANSF OPTIONS RED BAND 20 6 CABLE BLK RED GRN POWER PACK WELD TRANSF RECEPT FOOTSWITCH WELD COPPER CABLE BAR SEE SPECS ABOVE FOR B C RED PRESSURE SWITCH BLU RED MAIN POWER Hi Lo INPUT DIGITAL DISPLAY 2 1 4 5 G ORN 1 2 4 5 BRN BLK TO DISPLAY CONNECTOR 5 PIN GRN...

Page 10: ... local Duro Dyne wholesaler INSTALLATION INSTRUCTIONS 1 For the Mach III Connect the Power Pack to a source of 208 240V 60 Amp power This service should be connected to a 60 amp disconnect box fitted with 60 amp slow blow fuses The Power supply line to the power pack pigtail should be 6 or heavier wire to minimize voltage losses The black and white wires are the power the green is ground Select 20...

Page 11: ... and components during use Should a problem arise simply press the footswitch and watch to see which indicator fails to illuminate A call to our Technical Services Dept at 1 800 899 3876 will quickly identify the component to order repair or adjust STARTING OPERATION 1 Never actuate the unit without metal over the mandrel or lower copper ground bar For maximum weld quality the metal should be in f...

Page 12: ... The pins weld to bare metal but can easily be removed 3 Pins weld to bare metal but remain on the weld tip as it retracts 4 The pins do not weld at all Before troubleshooting always check 1 Air pressure for a minimum of 80 PSI during usage of unit 2 The input Voltage for a minimum of 208V 3 The Weld Timer is set properly 4 The Upper and the Lower Weld tips for extreme wear It may become necessary...

Page 13: ...not correct replace the Weld Timer 0 24VAC 0 Power Initiate and Weld Timer Indica tors are function ing Feed Reed Switch indicator is not functioning Feed Reed Switch Indicator goes on and off with every cycle Feed Reed Switch The Feed Reed Switch is a safety that will not allow the machine to operate if the Feed Cylinder has not fully retracted To test the Feed Reed Switch jump terminals 7 and 9 ...

Page 14: ...tom If this voltage is present now check the voltage 24VAC approx at the terminals 3 and 6 in the Trolley Terminals 3 and 6 should go from 24VAC to 0 and back to 24VAC with every cycle If this is correct the Dwell Reed Switch is functioning properly If the voltage reading is incorrect check the Dwell Reed Switch position To check the Dwell Reed Switch position first loosen the reed switch set scre...

Page 15: ...d blow out all Air Lines Remove and clean the Ex haust Muffler Reconnect the Air Lines and the muffler C Feed Cylinder C Turn the power and air off Check the Feed Cylinder and the Pusher With Pawl for binding Move the Pusher With Pawl in and out The Pusher With Pawl should move in and out with a slight resistance D Feed Solenoid D If the above procedures check out and the Feed still has sluggish m...

Page 16: ...lace 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 ...

Page 17: ...ators are functioning in cluding the Weld Indicator on the frame All lights flash in sequence Weld Transformer To test the primary of the Weld Transformer check the voltage at the terminals L1 and T1 on either of the Weld Relays They should go from 208 230 VAC approx to 0 and back to 208 230 VAC approx every time the machine cycles Now test the secondary output voltage Place the meter leads on the...

Page 18: ...f there is 208 230VAC at terminals 1 and 3 replace the Vibrator Speed Control F Vibrator Coil F Measure the resistance at the plug two outside pins of the Vibrator Base The resistance reading should be approximately 60 ohms If this reading is not correct replace the Vibrator Coil Vi b r a t o r v i brates but not enough to move weld pins N A A Vibrator Speed Control A To test the Vibrator Speed Co...

Page 19: ...und bar 18056 Locking knob 18065 2Amp Circuit Breaker 18066 220V Phase Control 27213 Flush mount camlock 39068 Receiving Board 39110 Pin feed switch 39273 Vibrator Base Plate 39296 Vibrator Bowl 39298 Vibrator Base 39306 Incoming Voltage Select Switch 39353 Anti friction strip 39359 Feed Channel Spacer 39691 C Clip 40102 Air hose 3 8 blue 40105 Air hose 1 4 yellow 40106 Air hose 1 4 blue 44008 Upp...

Page 20: ...ELD TRANSF RECEPT FOOTSWITCH WELD COPPER CABLE BAR SEE SPECS ABOVE FOR RED PRESSURE SWITCH YEL 82k BLK GUN SWITCH BLK YEL BLU B L K SOL 1 FEED BLK SOL 2 DWELL SPARES YEL RED GRN RECEPT GUN SWITCH B L K BLK Y E L RH M SUPPLY 6GA R VIBRATOR COIL WELDTRANSF OPTION WHT YEL R E D RED 8GA BLK 8GA WHT W H T RED R 1k TB 3 B L K T 5 T 1 0 T9 T11 T1 T2 T3 RELAY BRD VIB CNTRL C O M M H M L M H 24v COIL CONTA...

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