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MAINTENANCE
D-1
MAXsa™ 22 & 29 WIRE DRIVES
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Only Qualified personnel should
perform this maintenance.
• Turn the input power OFF at the
disconnect switch or fuse box
before working on this equipment.
• Do not touch electrically hot parts.
ROUTINE MAINTENANCE
• Check weld cables, control cables and gas hoses for
cuts.
• Clean and tighten all weld terminals.
• Inspect and clean drive rolls and inner wire guide
and replace if worn.
PERIODIC MAINTENANCE
• Every six months check the motor brushes. Replace
them if they are less than 1/4" long.
• Every year inspect the gearbox and coat the gear
teeth with a moly-disulfide filled grease. DO NOT
use graphite grease.
CALIBRATION SPECIFICATION
All calibration is factory set on the MAXsa™ Wire Drive.
To verify the wire feed speed:
• Adjust the wire feed speed to 100 in/min (2.54m/min)
and provide a COLD FEED Signal.
• Measure the actual wire feed speed with a calibrated
wire feed speed tachometer K283).
• The measured wire feed speed should be within ±2%
of the set value.
NOTE: If a K283 is not available, feed wire for 15 sec-
onds and measure the wire. Repeat several
times to get an average measurement. It should
be 25” (635mm) +/-2%.
SENSE LEAD FUSE
There should never be any current flowing through
the sense leads! The sensing lead circuit is current
protected in the Power Wave
®
AC/DC 1000 SD.
If the MAXsa™ 22 & 29 Wire Drives are used in an
older system, a fuse in series with the #21 sense lead
in the wire drive Connection Box protects the sense
lead circuit from weld current due to incorrect configu-
ration. If this fuse ever opens, check the sense lead
configuration to ensure proper connections. The fuse
must be replaced with a comparable fuse with a rating
of less than 1 amp before welding. The fuse being
open or missing would have the same effect on the
welding as having a disconnected sense lead.
WARNING