Operation Manual

56
A7 TIG Orbital System 300© Kemppi Oy 2016 1615
OPERATING MANUAL
6.3 Weld head maintenance
Field maintenance of the 300 series weld heads is minimal.
There are no repetitive lubrication requirements within
the weld head as all bearings are self-lubricated or dry.
Gears are pre-lubricated at assembly or run dry due to low
speeds and light loads.
Consult the factory if any apparent internal machine
package problem develops. While eld maintenance, such
as motor replacement, is possible with standard hand tools,
some complex sequences, techniques, and adjustments may
require specic procedures. Contact Kemppi to provide rapid
turn-around service for all equipment.
6.3.1 External maintenance
The roller chain uses sealed, permanently lubricated
roller bearings, and no lubrication is required. Inspect and
clean the oscillation shaft, on which the torch and AGC
mechanism mount, to remove any debris or weld spatter.
6.3.2 Low profile kit installation
To achieve the minimum radial clearance of 51 mm (2"),
you must change two components on the weld head.
• Filler wire spool mount; and
• Torch back cap.
The standard 1 kg. ller wire spool is mounted to the weld
head with one socket head screw.
1. Remove the screw using the hex driver supplied in
the tool kit.
2. Replace this with the special 0,5 kg. low prole
spool mount.
3. Replace the torch back cap with Plug P/N 102727-1
to obtain a minimum radial clearance.
6.3.3 Torch cable replacement
You can replace the torch cable in the eld if necessary.
Exceedingly worn or damaged torch cables can be rebuilt
by the factory.
1. Remove the grey PVC cover from the rear of the
tractor housing by removing the Allen head screws
retaining it in place.
2. Remove the round PVC cap from the back end of
the tractor housing.
3. Also remove the small PVC retaining clamp from
the forward end of the tractor housing.
4. Remove the torch and insulator block from the
AGC bracket by removing the two at socket head
screws.
5. Disconnect the water inlet line where it enters
the rear of the machine package housing by
unthreading the brass collar.
6. Remove the hose o the barbed tting.
7. Disconnect the hose where it exits the front end of
the machine housing on its way to the torch. Use a
at bladed screwdriver to unscrew the brass tting.
8. Gently pull the connector out of the cavity at the
rear of the tractor housing.
9. Disconnect the connector.
10. Remove the old torch cable.
11. Reinstall the new torch cable by positioning the
hoses in the appropriate machined grooves on
the tractor housing and reversing the procedure
outlined above.
6.3.4 Maintenance of the wire feed nozzle
Occasionally the wire feed nozzle can become clogged up
by metal shavings and other debris brought in by the ller
wire passing through it.
• Clean or replace the ller wire nozzle if this
occurs.
The symptom of this problem is erratic wire exit from the
wire nozzle, especially when using copper-coated wire as
the coating can ake o under the pressure of the wire
feeder drive roll.
Occasionally clogging results from the misalignment of
the wire as it enters the ire feed mechanism.
1. Check to see that the short segment of ller wire
conduit is properly lined up with the "V" machined
in the drive roll.
2. If this is not the case, reposition the conduit
by loosening the clamp retaining it and then
retightening.