Profax AEC 200-4D - Manual (Page 10)

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G. GAS VALVE
1. Remove front cover.
2. Remove the four screws on the rear cover to release the gun housing and handle.
3. Remove the C-clip from either end of the trigger retaining pin and remove the pin, trigger and tension spring.
4. Remove the brass valve retaining body and diaphragm from the drive housing.
5. Install the new diaphragm and valve retaining body into the drive housing.
6. Reinstall the trigger tension spring, trigger and trigger pin onto the gun handle and secure with the C-clip removed in step 3.
Make sure that the trigger is connected to the gas valve.
7. The gas valve should activate and gas should flow before the micro switch starts the motor. This allows for a preflow and
postflow of shielding gas to prevent cratering and porosity. Adjust when the micro switch activates with the adjusting set screw
beneath the metal trigger tab or by bending the tab itself or both. The micro switch should activate approximately 1/8” before the
trigger bottoms out against the handle.
8. Reinstall the housing and handle to the rear cover with the four screws removed in step 2 making sure not to pinch any wiring.
H. CONTROL CABLE
1. Remove front cover.
2. Remove the four screws on the rear cover to release the gun housing and handle
3. Unplug the control cord from the PC board.
4. Remove the cable /hose from the drive housing.
5. Remove the control cord clamp.
6. Remove the screw securing the rubber support sleeve and carefully remove the sleeve with the cable /hose and control cord.
7. Pull the cable/hose out of the rubber suppor t sleeve and then remove the control cord.
8. Push the PC board plug end of the new control cord through the rubber suppor t sleeve. Then slide the cable/hose through the
sleeve. NOTE: A lubricant may be necessary on the cable/hose to allow easier insertion.
9. Connect the cable/hose to the drive housing and tighten.
10. Secure the new control cable to the rear cover with the control cord clamp removed in step 5.
11. Route the new control cord under the cable/hose and connect the plug to the PC board at Red terminal.
12. Slide the rubber suppor t sleeve up and carefully insert into the rear cover and secure with the screw removed in step 6.
13. Reinstall the gun housing and handle to the rear cover using the four screw removed in step 2. Be careful not to pinch any wiring.
I. CABLE / HOSE
1. Remove front cover.
2. Remove the four screws on the rear cover to release the gun housing and handle
3. Unplug the control cord from the PC board.
4. Remove the cable /hose from the drive housing.
5. Remove the control cord clamp.
6. Remove the screw securing the rubber support sleeve and carefully remove the sleeve with the cable /hose and control cord.
7. Pull the old cable/hose out of the rubber suppor t sleeve.
8. Slide the new cable/hose through the rubber suppor t sleeve. NOTE: A lubricant may be necessary on the cable/hose to allow
easier insertion.
9. Connect the cable/hose to the drive housing and tighten.
10. Secure the control cable to the rear cover with the control cord clamp removed in step 5.
11. Route the control cord under the cable/hose and connect the plug to the PC board at Red terminal.
12. Slide the rubber suppor t sleeve up and carefully insert into the rear cover and secure with the screw removed in step 6.
13. Reinstall the gun housing and handle to the rear cover using the four screw removed in step 2. Be careful not to pinch any wiring.
J. MULTIPIN CONTROL CORD CONNECTORS
® ® ®
1. CompArc , Miller and Thermal Arc 14 pin connectors. 3. “PROFAX” P250SG & P300SG only 10 pin connector.
a. Black wire to pin “G” a. Black wire to pin “E”
b. White wire to pin “A” b. White wire to pin “C”
c. Green wire to pin “B” c. Green wire to pin “D”
®
2. Millermatic 250X only 10 pin connector.
a. Black wire to pin “J”
b. White wire to pin “D”
c. Green wire to pin “G”
A. DRIVE ROLL
1. Unlatch swing-out arm and rotate out away from drive roll.
2. Remove palnut from end of motor shaft.
3. Remove drive roll from shaft.
4. Install new drive roll by aligning keyway and pushing roll down onto motor shaft fully against stop.
5. Replace palnut.
6. Close swing-out arm and adjust tension.
B. DRIVEN ROLL
1. Unlatch swing-out arm and rotate out away from drive roll.
2. Remove one of the C-clips from the driven roll bearing pin.
3. Remove the bearing pin and driven roll.
4. Remove the nylon bushings from the old roll and install into the new roll.
5. Install the new driven roll by inserting the bearing pin and replacing the C-clip.
6. Close swing-out arm and adjust tension.
C. MOTOR
1. Remove front cover.
2. Remove the four screws on the rear cover to release the gun housing and handle.
3. Unplug the motor from the PC board.
4. Remove the three screws holding the handle to the drive housing and separate. Retain the motor insulator and O-ring.
5. Remove the motor from the gun handle.
6. Remove the drive roll from the old motor and install onto the new motor.
7. Install the new motor into the gun handle and replace the O-ring and insulator.
8. Assemble the gun handle and housing together making sure that the motor wires fit into the groove provided in the handle.
9. Reassemble the spool gun making sure that the motor wires do not get pinched between the housing and the rear cover.
10. Plug the motor onto the PC board at the Blue terminal.
D. PC BOARD
1. Remove front cover.
2. Unplug the four plugs from the PC board.
3. Remove the three nylon PC board securing screws and lift the PC board from the spool gun.
4. Install the new PC board and secure with the three nylon screws removed in step 3.
5. Reconnect the plugs to the PC board as follows:
a. Motor plug to Blue terminal.
b. Pot plug to Yellow terminal.
c. Control cord plug to Red terminal.
d. Switch plug to White terminal.
E. MICRO SWITCH
1. Remove front cover.
2. Remove the two switch securing screws and insulator.
3. Remove the four screws on the rear cover to release the housing and handle.
4. Unplug the switch from the PC board. P2 pins 3,4,5 & 6.
5. Remove the three screws holding the handle to the drive housing and sperate enough to remove the switch and wires.
6. Place the new switch wires into the handle wire groove and assemble the handle and drive housing back together using the
screws removed in step 5.
7. Secure the switch insulator and new switch to the handle using the screws removed in step 2.
8. Plug the switch to the PC board at the White terminal.
F. POTENTIOMETER
1. Remove front cover.
2. Unplug the potentiometer from the PC board.
3. Remove the knob and brake nut from the potentiometer and remove the potentiometer from the holding bracket.
4. Install the new potentiometer into the holding bracket and secure with the brake nut.
5. Install the potentiometer knob so that it will point to “0” when the potentiometer is at minimum.
6. Plug the potentiometer to the PC board at the Yellow terminal.
PARTS REPLACEMENT PROCEDURES