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PRO WELD INTERNATIONAL AG-900, Operation & Maintenance Manual

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PRO WELD INTERNATIONAL AG-900 Operation & Maintenance Manual Download Page 19

AG-900 

PRO  WELD 

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PAGE 12 

Summary of Contents for AG-900

Page 1: ...OPERATION MAINTENANCE OPERATION MAINTENANCE OPERATION MAINTENANCE OPERATION MAINTENANCE MANUAL MANUAL MANUAL MANUAL H D ARC GUN H D ARC GUN H D ARC GUN H D ARC GUN AG AG AG AG 900 900 900 900 ...

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Page 3: ...P 3 7 0 WELD TEST AND INSPECTION 7 7 1 WELD TEST 7 7 2 WELD INSPECTION 7 7 3 CAUSES OF POOR OR ERRATIC WELDS 7 7 4 TROUBLE SHOOTING POOR WELDS 9 8 0 MAINTENANCE 9 8 1 WELD CABLE REPLACEMENT 9 8 2 CONTROL CABLE REPLACEMENT 9 8 3 DISASSEMBLY OF GUN 10 8 4 GUN MAINTENANCE 10 8 5 RE ASSEMBLY 11 PARTS LIST GUN ASSEMBLY ARC STD HD 12 9 0 TROUBLE SHOOTING GUIDE 14 ...

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Page 8: ...y parts or accessories against failures resulting from misuse abuse improper installation maladjustment or use not in accordance with the operating instructions furnished by the manufacturer The warranty is valid only when studs are purchased from sources approved by the manufacturer or are of identical specifications to the manufacturer s 3 0 SUGGESTED SAFETY PRECAUTIONS In any welding operation ...

Page 9: ... diameter range of 5 8 through 1 1 4 inches Refer to figure 4 1 for weight and size specifications 5 0 UNPACKING There is very little to do when unpacking your ARC Stud Welding gun Your Stud Welder comes complete with all the accessories and tool required for set up adjustment and maintenance Aside from the correct chuck ferrule grip and any special accessories required for your application your A...

Page 10: ...nd no contact occurs between the stud and the ferrule during retraction or forward plunge of the stud Tighten the locking screws after centering the stud 3 The Plunge Length is the amount of stud exposed beyond the ferrule during initial set up Set the plunge by loosening the leg adjusting screws and moving the foot until the stud extends 1 8 to 3 16 past the end of the ferrule Tighten the leg adj...

Page 11: ... 8 5 Adjustment of Free Travel With the free travel adjustment sleeve screwed fully in clockwise there is no free travel when the plunge length plus the lift height adds up to be less than 7 16 inch the maximum stroke of the damper To increase the free travel back out counterclockwise the free travel adjustment sleeve refer to figure 6 3 Each full turn provides 062 inch of additional free travel T...

Page 12: ... of the stud and the adjacent metal of the base plate will be melted by the weld arc The gun will then plunge the stud into the molten pool extinguishing the arc to end the controlled portion of the weld cycle DO NOT MOVE THE GUN DURING THE WELD CYCLE 10 After the controlled weld cycle allow the molten metal to solidify briefly with the work surface to assure completion of the cycle about an extra...

Page 13: ...ifting hook on the Armature assembly cocks The gun is in the The timer times out Gun solenoid is de energized Lifting ring is uncocked by lifting ring spring Armature assembly is returned to relaxed state by armature return spring Lifting rod is no longer engaged by lifting ring and returns to relaxed state The main spring plunges the stud against the base plate Figure 6 4 GUN OPERATION FLOWCHART ...

Page 14: ...sults In an acceptable weld failure will occur in the stud material or tear out of a thin base plate Failure in the weld requires adjustment of procedure weld time and current setting 7 2 Weld Inspection Weld quality can be visually inspected Refer to Figure 7 1 as a reference to the quality of the weld 7 3 Causes Of Poor Or Erratic Welds 1 Loose chuck Does not grip stud tightly replace Not enough...

Page 15: ... 1 WELD INSPECTION GOOD STUD WELD A good full fillet STUD HANG UP Adjust foot to insure the stud is centered in the ferrule COLD WELD Increase weld current and or weld time HOT WELD Reduce weld current and or weld time PAGE 8 ...

Page 16: ...ment Remove legs by loosening set screws 31 Remove chuck and adapter 1 Take the weld cable 32 off connector stud 2 Loosen screws 35A in cable guide assembly 35 and remove the clamp 35B Remove the tape which holds the control cable to the weld cable When replacing the weld cable it should be clamped 8 1 4 from the center of the lug and untwisted to relieve the stranding Failure to do this will caus...

Page 17: ... and unscrew adjustable core 21 Do not unscrew loosen or remove rear coil yoke 20 or gun coil 18 8 4 Gun Maintenance If the gun motion becomes sluggish or erratic the gun should be disassembled cleaned and lubricated A Disassemble the gun as described Blow or wipe the gun body and parts clean B The inside diameters of adjustable core screw the lifting ring and mating diameters on the lifting rod s...

Page 18: ...unge damper into the front cover 6 Screw the damper cover 14 in place Inspect and replace if necessary the front bearing 5 inside the front cover 5 Install lifting rod 7 through rear of front cap 6 Engage the hook of the lifting rod on the spool of the plunge damper Attach the shaft extension 4 to the lifting rod 6 Re install the front cap and lifting rod into gun by inserting the lifting rod thro...

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Page 20: ...N 105 0024 19 WAVE WASHER 102 0117 ITEM DESCRIPTION PART NO 20 REAR COIL YOKE 301 0016 21 LIFT ADJ SCREW 301 0008 22 REAR CAP 033 493 23 SCREW 8 32 X 3 4 PAN HD 037 521 24 TRIGGER BUTTON 302 0013 25 SNAP RING 302 0023 26 TRIGGER SPRING 302 0016 27 HANDLE COVER 302 0009HD 28 TRIGGER SWITCH 302 0010 29 SCREW 10 32 X 1 2 OVAL HD 115 0009 30 SCREW 8 32 X 1 4 SET 115 0010 31 SCREW 5 16 18 X 3 8 SET 037...

Page 21: ...sassembly and clean Misalignment of accessories Re align fastener in center of i e legs foot piece grip by loosening the screws holding the foot and the legs Lift incorrectly set Adjust lift to recommend settings See section Set up of Weld Gun for suggested settings Weld quality appears Faulty or loose ground Clean area for grounding inconsistent from one connection Repair or tighten clamp weld to...

Page 22: ...ouble shooting should be done by qualified personnel trained to work on this type of equipment PROBLEM POSSIBLE CAUSE REMEDY Weld quality continued Poor quality fasteners Loose chuck Replace chuck Gun lifts but fastener Loose chuck Replace chuck Does not pull away from The work plate Accessory misalignment See previous problem for re alignment suggestions PAGE 15 ...

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