
TABLE OF CONTENTS
SECTION 7:
MAINTENANCE ....................................................................................... 7-1
7.01 Subsystem Test and Replacement Procedures ............................................... 7-1
7.1.1 Preparation ............................................................................................ 7-1
7.1.2 Test and Replacement Parts List ........................................................... 7-1
7.02 Service Tools ................................................................................................. 7-4
7.2.1 Tools and parts ...................................................................................... 7-4
7.2.2 Notes of disassembly and assembly ..................................................... 7-4
7.03 Replacement Procedure ................................................................................. 7-5
7.3.1 PCB1 (WK-5713) and Primary Diode D1 ............................................... 7-6
7.3.2 PCB2 (WK-5417), Capacitor C1 and Resistor R1 .................................. 7-8
7.3.3 PCB3 (WK-5609) and T1 “Transformer” ............................................. 7-10
7.3.4 PCB4 (WK-5449) ................................................................................. 7-11
7.3.5 PCB5 (WK-5548) ................................................................................. 7-12
7.3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” ................................. 7-13
7.3.7PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” .................................. 7-14
7.3.8 D2 and D3 “Secondary Diode” ............................................................ 7-15
7.3.9 C.C. “Coupling Coil” and FCH1 “Reactor” ............................................ 7-15
7.3.10 CT1 “Hole Current Trans” .................................................................. 7-17
7.3.11 FAN1 “Cooling Fan” ........................................................................... 7-18
7.3.12 HF UNIT1 “High Frequency Unit” ....................................................... 7-19
7.3.13 SOL1 “Solenoid GAS Valve” .............................................................. 7-20
7.3.14 C101-C102 “Capacitor”, L101 “Ring Core” and S1 “Switch” ............. 7-21
7.3.15 CON1 “Remote Receptacle” .............................................................. 7-22
7.3.16 TH1 “Primary Thermistor” ................................................................ 7-23
7.3.17 TH2 “Secondary Thermistor” ............................................................ 7-22
7.3.18 C103 “Capacitor” and L102 “Reactor” ............................................... 7-24
7.3.19 L103 “Reactor” .................................................................................. 7-24
7.3.20 C2 “Capacitor” and R2 “Resistor” ..................................................... 7-25
APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1
APPENDIX 2: PARTS LIST ................................................................................ A-2
APPENDIX 3: CONNECTION WIRING GUIDE ........................................................... A-6
APPENDIX 4: INTERCONNECT DIAGRAM ............................................................... A-8
APPENDIX 5: DIODE TESTING BASICS ................................................................. A-10
CIGWELD LIMITED WARRANTY
Terms of Warranty – December 2007
Warranty Schedule – December 2007
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover