Duro Dyne 40112, Owner'S Manual

Page 1: ... OWNER S MANUAL AUTOMATIC BULK FEED PINSPOTTER M A C H I I 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 ...

Page 2: ...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 c...

Page 3: ...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 Pla...

Page 4: ...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 ...

Page 5: ... 5 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 ...

Page 6: ... 6 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 ...

Page 7: ...4030 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 ...

Page 8: ... 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 ...

Page 9: ...51 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 ...

Page 10: ...upply 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 w...

Page 11: ... 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 ...

Page 12: ... 12 WIRING DIAGRAM FG MACH I ...

Page 13: ... 13 WIRING DIAGRAM FG MACH II ...

Page 14: ...ibutor 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 scre...

Page 15: ...onnections 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 categori...

Page 16: ...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 ins...

Page 17: ... indicators are functioning F e e d r e e d s w i t c h 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 I...

Page 18: ...is 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 an...

Page 19: ... 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 p...

Page 20: ...well 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 u...

Page 21: ...oltage at the terminals L1 and T1 on the Solid State Relays They should go from 208 230 VAC to 0 and back to 208 230 VAC every time the machine cycles Now test the secondary output voltage Place meter leads on copper bars coming out of the transformer s and test the voltage every time the machine is cycled The Mach 1 Transformers should read approximately 5VAC 2 5 VAC x 2 5VAC The Mach 2 should re...

Page 22: ... indicator light still does not function replace the Vibrator Sensor D Vibrator Control Relay Board To check the Vibrator Control Relay test the voltage 24VAC at terminals T2 and T5 There should be 24VAC at these terminals when there is no weld pin at the Track Sensor If this reading is correct Vibrator Sensor now check the voltage 208 230VAC at terminals T1 and T11 on the relay board When the mai...

Page 23: ...age Select Switch 39353 Anti friction strip 39359 Feed channel spacer PARTS LIST 40102 Air hose 3 8 blue 40105 Air hose 1 4 yellow 40106 Air hose 1 4 blue 44001 Vibrator sensor cord 44002 Vibrator sensor 44003 Vibrator sensor bracket 44006 Vibrator socket guard 44007 Vibrator fuse and bracket 44008 Upper feed track casting 44009 Upper track side rails 44010 Lower track casting 44011 Lower track si...

Page 24: ... 24 MACHINERY DIVISION 2019 Duro Dyne Corporation Printed in USA 6 2019 BI018401 M A C H I I ...