Duro Dyne Mach I User manual

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OWNER’S
MANUAL
AUTOMATIC BULK
FEED PINSPOTTER
MACH II
MACH I / MACH II
MACH I / MACH II
MACHINERY
DIVISION
Owner’s Manual for
Mach I:
SN# 40112 to 40384
Mach II:
SN# 41044 to 41167
Approx:
March ‘05 to June ‘09

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INTRODUCTION
Duro Dyne is proud to introduce the next generation bulk feed con-
cept of our popular FG-1 pinspotter. The Mach I and Mach II Pinspot-
ters were designed utilizing the best of current technologies to
provide greater power and reliability for insulation fastening.
Trouble free service was the foundation on which the original FG-1 was
built, with proven solid state components located for easy access.
The Mach I and Mach II series continue this concept and bring it
to a new level of reliability, serviceability and efficiency.
This Guide is designed to help you set up and operate your Mach I
or Mach II at peak performance for years to come.
IMPORTANT
Always follow manufacturer’s recommendations for proper safety
and handling procedures for all materials used in conjunction with
this machine as outlined in Manufacturer’s Safety Data Sheet
(MSDS) for each 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 discretion) at no cost if the faulty
component is returned freight prepaid to the nearest Duro Dyne
Service Department.
The warranty does not apply to expendable parts or repairs or service
due to improper maintenance or operation procedures.
Duro Dyne products have been engineered to maximize operator safety.
Unauthorized modification of this product will void the warranty.
All warranty claims must be accompanied by a serial number, date
of purchase and the name and address of the distributor it was
purchased from.
TABLE OF CONTENTS
Installation Instructions 10
Introduction 2
Maintenance 14
Operation 10
Parts List 23
Parts Locator 3-9
Servicing 15
Troubleshooting 16-22
Warranty 2
Wiring Diagrams 12-13

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17340 Vibrator Bowl
17368 2 inch Vibrator Bowl
17341 Vibrator Coil
44004 Vibrator Line Cord
17079 Vibrator Foot
17338 Vibrator Base Plate
17257 Vibrator Support Casting
44045
Weld Cable Guard
17317 Feed Speed Control
44014 Feed Solenoid
17364 Feed Cylinder
17269 Feed Cylinder Bracket
17351 Pusher and Pawl
17266 Feed Channel
17348 Feed Channel Plate
44013 Feed Channel Spacer
17339 Vibrator Base
44001 Vibrator Sensor Cord
44002 Vibrator Sensor
44003 Vibrator Sensor Bracket
44008 Upper Feed Track
44016 Power Bar
44056
Upper Dwell Cylinder Bracket
17359 Bracket Insulator
44009 Upper Track Side Rails
44011 Lower Track Side Rails
44010 Lower Feed Track Casting
44017 Weld Cable
17394 Short Shaft Extension
17203 Fiber Insulator
17190 Replacement Plates
17192 Lower Weld Tip
17189 Replacement Plates
17191 Upper Weld Tip
17352 Upper Tip Retainer
17376 Lower Mandrel
PARTS LOCATION
DWELL & FEED ASSEMBLY
17133

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44043 Dwell Cover
44044 Feed Cover
17377 Air Regulator
17372 Footswitch
44023 Control Module
44046 Component Module
44035 MACH I Power Pack
44036 MACH II Power Pack
44037 Power Pack Cover
PARTS LOCATION
FRAME ASSEMBLY

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44041 Line Cord
44042 Line Cord Strain Relief
(Not Shown)
44040 Mach II Weld Transformer
44019 Weld Cable Camlock
17327 Footswitch Receptacle
PARTS LOCATION
44036 MACH II POWER PACK

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PARTS LOCATION
44035 MACH I POWER PACK
17209 Line Cord
17210 Strain Relief
44038 Mach I Right Transformer
44039 Mach I Left Transformer
17327 Footswitch Receptacle

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PARTS LOCATION
CONTROL CONSOLE
44026 Weld Poteniometer
39110 Pin Feed Switch
44025 LCD Display
44024 Main On/Off Switch
44023 Control Module
44029 Relay Selector Switch
44030 Troubleshooting Display Board
44008 Upper Feed Track
44031 Vibrator Potentiometer
44027 Knob
44032 Vibrator Lamp
44033 Vibrator Power Switch
44034 Weld Lamp
44010 Lower Feed Track Casting
44018 Weld Cable Retainer Block
17333 Vibrator Speed Control
Located Inside Control Module
17256 Vibrator Socket
44006 Vibrator Socket Guard
44007 Vibrator Circuit Breaker
44027 Knob

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44008 Upper Feed Track Casting
44021 Head Mounting Plate
17359 Bracket Insulator
17363 Dwell Reed Switch
17231 Dwell Cylinder
44015 Dwell Solenoid
44057 Bracket Insulator
17237 Lower Dwell
Cylinder Bracket
17325 Pressure Switch
39353 Anti Friction Strip
44010 Lower Feed Track Casting
44056 Upper Dwell
Cylinder Bracket
17363 First Pulse Reed Switch
(not shown)
44020 Head Terminal Strip
17356 Adjustable Muffler
17363 Feed Reed Switch
PARTS LOCATION
HEAD & FEED ASSEMBLY

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17319 Dwell Extend Timer
17222 Terminal Strip-
Low Voltage
17323 Short Cycle Relay
17302 Weld Timer
44090 Vibrator Control Relay Board
44051 Relay Board
17323 First Pulse Relay
17222 Terminal Strip-
Low Voltage
44091 24V Multi-Tap Transformer
44052 12 Volt DC Power Supply
44048 Terminal Strip- High Voltage
44047 Power Contactor 39306 Incoming Voltage Selector Switch 44053 Weld Relay
17318 Feed Timer
44054 Heat Sink
44091 24V Multi-Tap Transformer
PARTS LOCATION
COMPONENT MODULE

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OPERATION
Mach I and Mach II INITIAL ADJUSTMENTS
1) Turn the power switch to “ON”.
2) Turn the vibrator switch to “ON”.
3) Add the weld pins to the hopper (vibrator bowl).
4) Adjust the vibrator speed so that the weld pins climb the spiral track inside the vibrator bowl without
vibrating off.
5) When the weld pins fill the track up to the proximity track sensor, the vibrator automatically shuts off.
6) Flip the head test switch to either the “WELD #1” or “WELD #2” position.
NOTE: Your Mach I and Mach II Pinspotter has two redundant weld circuits. In the event that the solid state
relay controlling the weld fails you may simply flip the switch to the other circuit and continue production.
A replacement Weld Relay should then be ordered through your local Duro Dyne wholesaler.
INSTALLATION INSTRUCTIONS
1a) For the Mach I -
Connect the power pack to a source of 208-230 V 30 Amp. power. The power supply line to the power
pack pigtail should be #8 (or heavier) wire to minimize voltage losses. The black and white wires are the
power, the green is ground.
1b) For the Mach II -
Connect the power pack to a source of 208-230 V 100 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.
2) Attach the foot switch to the foot switch socket on the rear of the power pack.
3) Connect the air line to the regulator. Adjust the regulator pressure to 80-85 PSI.
4) Plug the vibrator power plug into the socket on the rear of the control panel.
TECHNICAL SPECIFICATIONS
Mach II
AIR REQUIREMENTS:
Input pressure 80 PSI.
ELECTRICAL:
Input voltage: 208-230 V 60 HZ
single phase. 100 amp service
Fuse for 60 amps. using slow blow fuses
TECHNICAL SPECIFICATIONS
Mach I
AIR REQUIREMENTS:
Input pressure 80 PSI.
ELECTRICAL:
Input voltage: 208-230 V 60 HZ
single phase.
Fuse for 30 amps. using slow blow fuses

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OPERATION DISPLAY
Your Mach I or Mach II Pinspotter is provided with an OPERATIONS DISPLAY to help identify the source
of the problem should your pinspotter fail to perform properly. Watching these lights will give you a clear in-
dication of the electrical flow of the various circuits and components during use. Should a problem arise, you
simply press the footswitch and watch to see which light fails to illuminate. A call to our Technical Services
Department at 1-800-899-3876 will quickly identify the faulty component for you to order or adjust.
STARTING OPERATION
1) Never actuate the unit without metal over the mandrel. For maximum weld quality, the metal should be in
flat contact with the mandrel. An adjacent table or roller on which the sheet metal rests must be either
exactly flush with, or slightly below, the top of the mandrel.
2) The WELD TIME controls the weld quality of the pinspotter. The display goes from 0 to 300. These num-
bers are for reference only and have no relationship with actual time. It is recommended that an initial
setting of 150 be used and then adjust up or down accordingly in reference to the quality of welds.
Weld time is the length of time the welding transformers are on. A fraction of a second is generally all
the time needed for a quality weld. Unnecessary weld time not only wastes energy but can also burn up
the pins. (If the pins glow red up to the washer, the weld time is set too high.) Always set the weld timer
to the minimum time required for a good weld.
3) Before beginning production, always “pre-test” with smaller pieces of the same gauge sheet metal thickness
and liner density you intend to use in the final production. The different densities and the thicknesses of
the liner may require adjustments of the weld timer setting. For example: heavier gauge steel, thicker liner,
higher density liner and/or longer clip pins may require longer weld time. To make sure, always pre-test
any adjustment before you go into the “finished production.” However, only change the weld timer settings
when a change in the materials results in inefficient welding or a poor quality weld.

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WIRING DIAGRAM
FG - MACH I

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WIRING DIAGRAM
FG - MACH II

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MAINTENANCE
1) To prolong the weld tip life and improve the weld
quality, it is imperative that the weld tips always
be kept clean. For best results, use a solvent to
remove the adhesive from tips; a wire brush to
remove any galvanizing deposits; and a fine emory
cloth to smooth the tip surfaces.
2) When lower weld tip becomes worn in one area,
loosen the locking cap screw and rotate the point
of wear away from the point of contact. If this
cannot be done because the lower weld tip is too
badly pitted, replace lower weld plate. Additional
lower weld plates can be ordered from your local
distributor.
3) Depending on usage and maintenance, the up-
per welding tip plate will have to be periodically
replaced. The replacement weld tip plates can be
ordered from your local distributor. To replace the
upper weld tip, loosen the locking cap screw and
remove the weld tip. Remove the plate by loosening
three (3) brass screws. Throw away the screws
and attach the new plate to the tip using three
brass screws supplied. Be sure to align the angled
section of the plate so it faces the feed mechanism.
Then lock the tip in place. Cycle the machine to check
the feeding.
4) If feeding is erratic, re-adjust the upper weld tip
height by loosening the lock nut and then turning
the dwell cylinder shaft clockwise to raise the tip;
counter-clockwise to lower the tip. Lock the tip in
position with the locking nut.

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SERVICING
A SIMPLIFIED STEP-BY-STEP PROCEDURE
Duro Dyne has called upon its many years of pinspotting experience in designing the Mach I and Mach II.
Your unit has been rigorously factory tested and inspected to provide many years of dependable service.
WHAT TO DO BEFORE YOU BEGIN TROUBLESHOOTING:
CONSULT THE MANUAL.
Most of the functional problems that occur are due to an oversight in the set-up, operational or normal
maintenance procedures. Therefore, you should re-check all “Set Up”, “Initial Adjustment”, “Operation” and
“Maintenance” procedures.
INSPECT THE UNIT
If the problem still persists, the next step is careful visual inspection. Turn off the electricity - that is, discon-
nect your Pinspotter from its power supply and carefully check the control box for loose, broken or disconnected
wires. Also check the air circuit for leaky air connections or cut hoses.
HOW TO IDENTIFY WELD QUALITY PROBLEMS
By weld we mean that the Power Pack is energized, sending a pulse of electricity through the clip pin, causing
it to begin to fuse to the sheet metal.
To properly troubleshoot the weld quality problems, you must first pinpoint the symptom by test welding the
clip pins to bare sheet metal. The symptom will then show up in one of four categories:
1) The pins weld to bare metal but not on lined work.
2) 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 and a maximum of 230V.
3) The Weld Timer is set properly.
4) The Upper and the Lower Weld tips for extreme wear.
It may become necessary to use a voltmeter and/or ohmmeter to perform some servicing procedures.
An Analog type is best. Our Technical Services Department will help you if necessary.

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TROUBLESHOOTING SECTION
Your Mach I or Mach II Pinspotter is equipped with a Digital
Function Display that will assist you in quickly locating the prob-
able cause should your machine fail to operate. While the display
can point you to a defective component, it is recommended that
an analog type volt meter be used to verify the indication. In some
cases a loose or broken wire could cause a false indication.
This troubleshooting section has been divided into separate
sections depending on the type of malfunction.
MACHINE DOES NOT OPERATE
PIN FEED PROBLEMS
DWELL CYLINDER PROBLEMS
PINS DO NOT WELD
POOR WELD QUALITY
VIBRATOR PROBLEMS
After determining the type of problem, go to that section,
cycle the machine watching the indicator lights and then follow
the instructions in that part of the chart. If further assistance is
needed you may call our Technical Services Department at 1-800-899-
3876 between the hours of 7am - 6pm EST.

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MACHINE DOES NOT OPERATE
SYMPTOM CORRECT
FUNCTION
INDICATOR
POSSIBLE
PROBLEM ACTION
No power
indicator.
Nodisplay.
Power indicator
goes on and off
with main power
switch.
(A) Power
supply.
(A) Check the incoming power (208-230VAC) at terminals #29 and #30
or L1 and L2 on the contactor.
(B) Contactor. (B) Check the voltage (24VAC+/-) at the coil of the contactor. If the voltage
is present, check the voltage (208-230VAC) at terminals T1 and T2 on
the contactor. If the voltage is present, the contactor is good. Proceed
to step (E). If the voltage at the coil is present and T1 and T2 have no
voltage replace the contactor. If the voltage at the coil is not present,
proceed to the next two steps (C and D).
(C) Main power
switch.
(C) Check the switch terminals B4 and B5. Terminals B4 and B5 should have
24VAC+/- when the switch is in the off position and 0 volts when the
switch is in the on position. If the voltage stays at 24VAC+/- replace
the switch. If the voltage stays at 0 volts proceed to step (D).
(D) 24VAC
Transformer.
(XSFMR-1)
(D) Check the transformer primary input voltage (208-230VAC) at terminal
L1 and L2. Check the transformer secondary voltage (24VAC+/-) at
the coil of contactor. If the voltage at the coil is not present and step
(C) is correct replace the transformer. (This transformer is for the
contactor only)
(E) 24VAC
Transformer.
(XSFMR-2)
(E) Check the transformer primary input voltage (208-230VAC) at terminal
T1 and T2. Check the transformer secondary voltage (24VAC+/-) at
terminals # 22 and # 24. If the voltage at terminals #22 and #24 is
not present replace the transformer.
(This transformer is for all the low voltage control circuits except for
the coil of the contactor)
Power indicator on.
Initiate
indicator is not
functioning.
Initiate indicator
goes on with
footswitch and
off after the
machine cycles.
Footswitch. Check the voltage (24VAC+/-) at terminals #17 and # 21 while depressing
the footswitch. This voltage reading should go from 0 to 24VAC. If this
voltage reading is not correct replace or repair Footswitch.
Power indicator on.
Initiate indicator
is functioning.
Weld timer indica-
tor is not func-
tioning.
Weld timer indicator
goes on and off
with every cycle.
Weld timer. Turn the weld time to the highest setting and check the voltage (24VAC+/-)
at terminals #14 and #17. This voltage should come on then go off
every time the footswitch is depressed. If this voltage reading is not
correct replace weld timer. (0 – 24VAC – 0)
Power,Initiate,
and Weld timer
indicators are
functioning.
Feedreedswitch
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 feed cylinder has not fully retracted. To test the feed reed switch jump
terminals #14 to #19 or #35 to #36. Now try to cycle the machine
with this jumper in place. If machine operates this means that the feed
reed switch is not functioning. This reed switch is located on the feed
cylinder and may be out of position. To check the position, turn power
off (remove jumper from pervious test) and loosen setscrews on reed
switch. Now put an ohmmeter on terminals #14 and #19 or #35 and
#36. Slide reed switch back and forth near the rear of the cylinder
until the meter reads continuity. Now lock setscrews. If this procedure
cannot be accomplice replace feed reed switch.
Power, Initiate,
Weld timer and
Feed reed switch
indicators are
functioning.
Dwell solenoid
indicator is not
functioning.
Dwell solenoid
indicator goes on
and off with every
cycle. (Stays on
150ms longer
than feed reed
indicator.)
Short cycle
relay.
Turn the weld time to the highest setting and check the voltage (24VAC+/-)
at the terminals #17 and #19. This voltage reading should go from 0
to 24VAC and then back to 0 every time the footswitch is depressed.
If this voltage reading is not correct recheck symptom. Now do the
same procedure at terminals #9 and #24. If this voltage reading is
incorrect replace relay.
Power, Initiate,
Weld timer, Feed
reed switch and
dwell solenoid
indicators are all
functioning.
All lights flash in
sequence.
(A) Air
pressure,
Adjustable
exhaust
Mufflers
and Dwell
cylinder.
(A) Check main regulator for proper setting (80psi). Now press yellow
test bottom located on the Dwell solenoid body. If the Dwell cylinder
does not operate check the adjustable exhaust mufflers on the dwell
solenoid for proper adjustment. If the mufflers are closed or restricted
it will not allow the dwell cylinder to operate. Also check the cylinder
by turning the air off and then move the shaft in and out. Shaft should
move freely. If the mufflers (these mufflers control the speed of the
up and down motion on the cylinder) are properly adjusted and have no
restrictions and the Dwell cylinder operates when the test bottom is
pressed proceed to step (B).
(B) Dwell
solenoid.
(B) Turn the weld time to the highest setting and check the voltage
(24VAC+/-) at terminals #9 and #24. The voltage reading should go
from 0 to 24VAC and back to 0 every time the footswitch is depressed.
If this voltage reading is correct replace the Dwell solenoid.

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PIN FEED PROBLEMS
SYMPTOM CORRECT
FUNCTION
INDICATOR
POSSIBLE
PROBLEM ACTION
Firstpulse
indicator is not
functioning.
First pulse indicator
turns on with
the first machine
cycle. Stays on
until main power
is turned off.
First pulse
reed
switch.
The First pulse reed switch sends power to the coil of the first pulse relay.
To check the reed switch, remove the wire that goes to terminal#4 on the
Dwell Delay Timer and then jump terminals #7 to #24 or #33 to #34.
With this jumper in place cycle the machine. If the machine feeds check
the reed switch position (First pulse reed switch should be mounted
to the middle off the dwell cylinder). If reed switch position is correct
replace First pulse reed switch.
First pulse
indicator is
functioning.
Dwellreed
switch input
indicator is not
functioning
Dwell reed switch
input indicator
turns on with
the first machine
cycle. Stays on
until main power
is turned off.
(A) First pulse
relay. (Coil)
(A) The first pulse relay (K2 on the DRP panel) should engage on the first
machine cycle and should stays engage until power is turned off. To
check the first pulse relay jump terminals #7 to #24 or #33 to #34.
With this jumper in place and the power on check the voltage (24VAC+/-)
on the DRP panel at TB10 terminals #1 and #2. If voltage is present
and the relay is engaged (Indicator on relay is on) proceed to step (B).
If the voltage is present and the relay is not engaged (No indicator on
the relay) replace the First pulse relay.
First pulse
indicator is
functioning.
Dwellreed
switch input
indicator is not
functioning.
Dwell reed switch
input indicator
turns on with
the first machine
cycle. Stays on
until main power
is turned off.
(B) First pulse
relay.
(Contacts)
(B) If the relay is engaged (Indicator on the relay is on) check the voltage
(24VAC+/-) at the terminals #6 and #4. If the voltage is not present
replace the First pulse relay. If the voltage is present proceed to
next step.
First pulse and
Dwell reed
switch input
indicators are
functioning.
Dwell reed
switch output
indicator is not
functioning.
Dwell reed switch
output indicator
turns on with
the first machine
cycle. Goes off
and then back on
with every cycle.
Dwell reed
switch
The Dwell reed switch is the upper of the two reed switches located on the
side of the Dwell cylinder. The Dwell reed switch initiates the feed timer.
To check the Dwell reed switch first cycle the machine once and then
check the voltage (24VAC+/-) at terminals #4 and #6. If the voltage is
not present recheck symptom. If this voltage is present now check the
voltage (24VAC+/-) at the terminals #4 and #5. Terminals #4 and #5
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 setscrews. Slide
the reed switch down and check the voltage at terminal #4 and #5.
The voltage should read 0. Now slide the reed switch up until terminals
#4 and #5 have 24VAC and then lock the setscrews. If this procedure
cannot be accomplice replace the Dwell reed switch.
First pulse, Dwell
reed switch
input and output
indicators are
functioning.
Feed solenoid
indicator is not
functioning
Feed solenoid
indicator goes on
and then back off
with every cycle.
Feed timer The Feed timer initiates the Feed solenoid. Check the voltage (24VAC+/-)
at the terminal #2 and #5. The voltage at terminal #2 and #5 should
go from 0 to 24VAC and back to 0 on every cycle. If this voltage reading
is incorrect replace the Feed timer. If the voltage reading is correct
proceed to next section. (This voltage is only present for 150ms. Some
voltmeters may not react fast enough to see this voltage)
Allindicatorsare
Functioning.
All lights flash in
sequence.
Feed solenoid,
Feed
cylinder, and
Pusher with
Pawl.
The Feed solenoid controls the Feed cylinder. To test the Feed solenoid
check the voltage (24VAC+/-) at terminals #2 and #5. Terminals #2
and #5 should go to 24VAC and back to 0 on every cycle. If correct
turn power and air off. Now try to move the Pusher with Pawl in and
out. The Pusher with Pawl should move easily. If so, replace the Feed
solenoid. If not, check for jammed Weld pins in the Feed channel or for
a damaged Feed cylinder. Also check the Feed speed control for proper
adjustment. (Located on the air line going to the Feed cylinder)
Feedcylinderdoes
not retract.
Feedsolenoid
indicator on
constantly.
Feed solenoid
indicator goes on
and then back off
with every cycle.
Feed timer. Remove the push-on connector from terminal #4 of the Feed timer. If Feed
cylinder retracts replace the Feed timer.
Feedcylinder
does not
retract.
Allindicatorsare
functioning
correctly
All lights flash in
sequence
(A) Feed
cylinder or
Pusher with
Pawl.
(A) Turn power off and inspect the Feed cylinder for air leaks. If there is no
air leaks turn the air off and slide the Pusher with Pawl in and out. The
Pusher with Pawl should go in and out with just a slight restriction.
(B) Feed
solenoid.
(B) To check the Feed solenoid turn the power off. If the cylinder does not
retract and step (A) above is correct replace Feed solenoid.

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SYMPTOM CORRECT
FUNCTION
INDICATOR
POSSIBLE
PROBLEM ACTION
Feedcollideswith
dwell.
All indicators are
functioning
correctly except:
Dwell reed switch
output and
Feed solenoid
indicators are
not coming on
in the correct
sequence.
Dwell reed switch
output indicator
turns on with
the first machine
cycle. Goes off
and then back on
with every cycle.
Feed solenoid
indicator goes on
and then back off
with every cycle.
Dwell reed
switch
The Dwell reed switch initiates the Feed timer. If this switch is malfunctioning
or out of position it will initiate the feed at the wrong time.
Refer to the action section on page 18 for Dwell reed switch possible
problem for instructions on how to check and adjust.
Sluggish
movementof
the Feed.
Allindicatorsare
functioning
correctly
All lights flash in se-
quence
(A) Feed Speed
Control.
(A) Readjust the Feed Speed Control located on the air line going to the
Feed cylinder.
(B) Air Lines. (B) Check the air lines for leaks and water in the air lines. If there is water
in the air lines, disconnect and blow out all air lines. Remove and clean
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 Feed in and out. The Feed 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
movement the problem may be the Feed solenoid. Remove the air
line from air inlet of the solenoid and spray a light oil in the solenoid.
Reconnect air line and cycle machine. If Feed still has sluggish movement
replace the Feed solenoid.
Feeddoesnot
place Weld pins on
Upper Weld Tip.
Allindicatorsare
functioning
correctly
All lights flash in se-
quence
(A) Feed Speed
Control.
(A) If the Feed Speed Control is open too much it may throw pins past
the Upper Weld Tip. Adjust Feed Speed Control so that it places the
pin on the Upper Weld Tip.
(B) Upper Weld
Tip.
(B) Check the Upper Weld Tip for Magnetism. Place a Weld pin under the
Upper Weld Tip. If the tip does not retain the pin or magnets feel weak
replace Upper Weld Tip.
(C) Pusher
with pawl.
(C) The Pawl (hinged part) on the Pusher may be damaged or missing. If
so replace Pusher with Pawl.

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DWELL CYLINDER PROBLEMS
SYMPTOM CORRECT
FUNCTION
INDICATOR
POSSIBLE
PROBLEM ACTION
Dwell cylinder does
not retract and
weld stays on.
Initiate, Weld
timer, Feed
reed switch,
Dwell solenoid
and Weld signal
indicators
are all on
Constantly.
All lights flash in
sequence
Weld timer. Remove the push-on connector from terminal #4 of the Weld timer. If Dwell
cylinder retracts and weld turns off replace Weld timer.
Dwellcylinderdoes
not retract and
weld stays on.
Initiate, Dwell
solenoid and
Weld signal
indicators
are all on
constantly.
All lights flash in
sequence
Short cycle
relay.
Test for voltage (24VAC+/-) at terminals #17 and #19. If the voltage is
present return to the step up above. If the voltage is not present,
now check the voltage (24VAC+/-) at the terminals #9 to #24, #18
to #22 and #17 to #22. If the voltage is present all the time on these
terminals replace the Short cycle relay.
Dwellcylinderdoes
not retract.
Dwell solenoid
and Dwell delay
indicators are
on constantly.
Dwell solenoid
indicator goes
on and off with
every cycle.
Stays on 150ms
longer than feed
reed indicator.
Dwell Delay
timer.
Remove the push-on connector from terminal #4 of the Dwell Delay timer.
If Dwell cylinder retracts replace the Dwell Delay timer.
Dwellcylinderdoes
not retract.
Allindicatorsare
functioning
correctly
All lights flash in
sequence
(A) Dwell
solenoid.
(A) Turn the power off. (If the Dwell cylinder shaft retracts recheck symp-
tom). Now try and lift the cylinder shaft up. If the cylinder shaft cannot
be lifted replace the Dwell solenoid.
(B) Dwell
cylinder.
(B) If the cylinder shaft can be lifted easily check the Dwell cylinder and
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 bad. Replace the
Dwell cylinder. If a slight air resistance is present on the up and down
motion replace the Dwell solenoid.
Sluggish movement
of the Welding tip.
All indicators are
functioning
correctly
All lights flash in
sequence
(A) Main air
regulator.
A) Adjust main air regulator (80psi).
(B) Air lines
and
Adjustable
mufflers.
(B) Check air lines for leaks or water in the air lines. If there is water in
the air lines, disconnect and blow out air lines. Remove and clean out
adjustable mufflers. Reconnect air lines and adjustable mufflers.
(C) Dwell
cylinder.
(C) Turn the power and air off. Check the Dwell Cylinder shaft for binding by
moving shaft in and out of the cylinder. A slight air resistance should be
present when the shaft is being moved in and out of the Cylinder.
(D) Dwell
solenoid
(D) If the above procedures check out and the Dwell cylinder still has
sluggish movement the problem maybe the Dwell solenoid. Remove the
air line from air inlet of the solenoid and spray a light oil in the solenoid.
Reconnect air line and cycle machine. If Dwell cylinder still has sluggish
movement replace the Dwell solenoid.