J-Head Operations and Maintenance Manual P/N 315-4110-901 Rev. K

J-HEAD
OPERATIONS AND MAINTENANCE MANUAL

P/N 315-4110-901 Rev. K
WWW.LIBURDI.COM
DATE SHIPPED:________________________
SERIAL NUMBER:______________________
Liburdi Dimetrics Corporation
2599 Charlotte Highway
Mooresville, NC 28117
1-704-230-2510
Contact Information
USA | tel:1-704-230-2510 | dimmkt@dimetrics.com
INTERNATIONAL | tel: 1-905-689-0734 | liburdi@liburdi.com
EUROPE | tel: +31-6-2036-1018 | liburdieurope@liburdi.com
NOTICE
Liburdi Dimetrics, Inc., has prepared this manual for use by Liburdi
Dimetrics' personnel and its customers as a guide for the proper installation,
operation and maintenance of Liburdi Dimetrics equipment. The contents of
this manual, including but not limited to all drawings, specifications or
information is proprietary and the property of Liburdi Dimetrics, Inc. Any
unauthorized use or disclosure of such contents or any of the drawings,
specifications or information contained herein for manufacture, sale or
otherwise is prohibited; nothing contained herein shall be reproduced, stored
or transmitted in whole or in part by any means whatsoever without the
express prior written permission of Liburdi Dimetrics, Inc. In receiving this
manual, the recipient acknowledges the proprietary nature of the material
and agrees to take all steps necessary to preclude disclosure of the manual
and the proprietary information contained herein to any third party and will
maintain the manual and proprietary information in strictest confidence.
DISCLAIMER
Liburdi Dimetrics does not warrant or assume responsibility for damage to

equipment not supplied by Liburdi Dimetrics, Inc.
Without specific written authorization, Liburdi Dimetrics does not warrant or

assume responsibility for damage to this weld head when it is used with
welding systems not manufactured or supplied by Liburdi Dimetrics, Inc.
ALL RIGHTS RESERVED UNDER THE COPYRIGHT LAWS

Copyright 1993 LIBURDI DIMETRICS, INC.
OPERATIONS AND MAINTENANCE MANUAL 315-4110-901

ii
SAFETY
Anyone who is working in industry should know the importance of safety,

both in the working environment and in their own personal work habits.
Safety training programs are sponsored by management, public agencies, and
insurance companies. Despite these good efforts, accidents annually cause
lost time on the job, painful injuries and needless death.
Good work habits are learned daily. As you begin your work on the Weld
Head and in the welding field, resolve now to learn and practice safe working
habits.
Voltages and current inside of the welding equipment may be lethal;

therefore, it is recommended that you read ALL of the Manuals and follow
our DANGER, CAUTION, WARNING and special NOTES as you study
these texts.
ATTITUDE & GENERAL RULES OF SAFETY
Labs, offices, manufacturing buildings, and all work areas are for ADULT
type of conduct. There should be no room for tricks, games, and general
"Horse Play" as this may cause injury or harm to yourself or others.
All work areas must have proper power, ventilation and light.
Storage areas must be kept clean and secure.
The use of temporary extension cords, fans, heaters, gas and water
connections should be discouraged.
Maintain a neat and orderly work area. Everything should have a place, and
everything should be in its place when not in use.
Obey all the posted warning signs. They are posted for your protection.
It is your responsibility to caution anyone you think is violating safety rules.
Work at a pace consistent with safety. Rushing to complete a procedure is

foolish and dangerous.
If a piece of equipment or tool is not working properly, either have it

repaired, or discard it and get a new one. Poor tools may be a large
contributor to an unsafe situation

iii
Report any unsafe condition you may detect so that it may be remedied.
Follow up on your report to see that it has, in fact, been done.
Consider every electrical circuit to be "LIVE" unless it is proven otherwise.
Be sure your hands are dry before operating or working around electric
motors, switches, plugs or receptacles.
Never allow anyone to turn power "On" or "Off" for you while you are working
on a piece of equipment. Do it yourself.
If you turn "Off" a piece of equipment and unplug it from the receptacle, tag
the plug before proceeding with your work to prevent someone else from
turning on the equipment.
If you turn "Off" a switch in a remote area that controls the area where you
will be working, make sure you hang a sign on the circuit alerting everyone
else that the circuit must not be activated. "DO NOT TURN ON THIS
CIRCUIT - (SIGN YOUR NAME DATE - TIME)" should be sufficient. A
better method would be to have a lock type of circuit breaker that may only
be activated by a key or physical lock and you have the only key.
Make sure you can locate ALL circuit breakers in the areas you work
regularly.
Locate ALL fire exits and Fire Extinguishers. Know the exits you are to use
in case of an emergency. Learn to use the proper fire extinguisher for the
various types of fires. Using the wrong type of extinguisher on electrical
equipment may prove lethal.
Know the location of First Aid supplies and how to use them.
Are there Fire Alarms that are audible in your area? If not, WHY NOT?
Do not work alone.
Wear eye protection (safety glasses or dark welding lenses), especially when
welding, soldering or in other hazardous areas.
Wear face shields when working around chemicals or when using the grinder.
When compressed air is used for cleaning, wear eye protection.

Dust, smoke, chips, shavings, and other loose items should be swept or blown
away from anyone in the area.

iv
Remove loose fitting clothing, ties, or scarves before operating rotating
machinery. Roll long sleeves above the elbow.
Wear closed shoes when working in labs or in industrial sites. Open toed
shoes or sandals should not be allowed in welding areas.
Long hair may become entangled in rotating machinery and cause severe
scalp and head injuries. Long hair is strongly discouraged.
Wear protective clothing when working around chemicals, radioactive

material, X-Ray or welding areas.
Always wash your hands after working with grease or chemicals.
Remove jewelry and any other ornamental objects that could be hazardous.
Keep the doorways, fire lanes, floors, aisles, and passageways clear.
Never leave tools where they may cause injury.
Keep tools from projecting over edges of benches or equipment.
Keep the doors to cabinets and drawers closed unless you need to gain access:
Then immediately close them again.
Don't test parts or soldering irons by feeling them with your hands or fingers.
It is best to pick up parts with a pair of pliers, gloves, or test them with a
piece of dampened towel first.
When you are finished with a soldering iron, return it to the holder. Never
pass a hot soldering iron to another person. Return it to the holder and let
the other person pick it up from there.
When performing a soldering operation, make sure the piece of work you are
working on is not electrically active.
These are just common sense rules: and by using

your own common sense when working around
rotating equipment or electrical apparatus, you
may contribute to safer conditions for both you and
your coworkers.

v
SAFETY INSTRUCTIONS
ARC WELDING SAFETY INSTRUCITONS AND WARNINGS
READ ALL OF THESE SAFETY INSTRUCTIONS AND WARNINGS
BEFORE USING THE PRODUCT.
WARNING
ARC WELDING CAN BE HAZARDOUS
PROTECT YOURSELF AND OTHER FROM POSSIBLE SERIOUS INJURY OR

DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL
CONSULTING WITH YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.
READ THE OPERATING & INSTRUCTION MANUAL BEFORE INSTALLING,
OPERATING, OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or
damage to other equipment or property if the operator does not strictly observe all
safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and
cutting. These practices must be learned through sturdy and training before using
this equipment. Anyone not having extensive training in welding and cutting
practices should not attempt to weld. Certain practices apply to equipment
connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled,
SAFETY IN WELDING AND CUTTING. This publication and other guides to what
you should learn before operating this equipment are listed at the end of these
safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR

WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
____________________________________________________________________________
ELECTRIC SHOCK CAN KILL

Touching live electrical parts can cause fatal shocks and severe burns. The
electorde and work circuit are electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live when the power is on. In
semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and
all metal parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
1. Do not touch live electrial parts.
2. Wear dry, hole – free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
(continued)
4. Disconnect input power or stop engine before installing or servicing this
equipment. Lock input power disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Instruction
manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment if
it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water to cool it
or lay it down on the ground or work surface. Do not touch holders
connected to 2 welding machines at the same time, or touch other people
with the holder or electrode.
(continued)
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground) circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts
at once.
13. In confined spaces or damp locations, do not use a welder with AC
output unless it is equipped with a voltage reducer. Use equipment with DC
output.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
____________________________________________________________________________
ARC RAYS CAN BURN EVES AND SKIN;

NOISE CAN DAMAGE HEARING.
Arc rays from the welding process produces intense heat and strong
ultraviolet rays that can burn eyes and skin. Noise from some processes
can damage hearing.
1. Wear a welding helmet fitted with the proper shade of filter (ANSI Z49.1
in Safety Standards) to protect your face and eyes when welding or
watching.
2. Wear approved safety glasses. Side shields are recommended.
3. Use protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material
(wool & leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Eye Protection Filter Shade Selector: Welding or Cutting, Goggles or Helmet (AWS A6.2-73)
Operations Electrode Size Filter Operations Electrode Size Filter

Metal Thickness Shade Metal Thickness Shade
or Weld Current No. or Weld Current No.
Torch Soldering ... not applicable ............. 2 Gas Tungsten Arc
Torch Brazing ...... not applicable ............ .3 or 4 Welding (TIG) ...... All .............................. 12
Oxygen Cutting Atomic Hydrogen
Light ............ < 1 in (25mm) ............ 3 or 4 Welding .............. All .............................. 12
Medium ......... 1-6 in (25 - 150mm) .. 4 or 5 Carbon Arc
Heavy ........... > 6 in (150mm) ........ 5 or 6 Welding .............. All .............................. 12
Gas Welding Plasma Arc
Light .............. < 1/8 in (3mm) ....... 4 or 5 Welding .............. All .............................. 12
Medium ........ 1/8 - 1/2 in (3-12mm) 5 or 6 Carbon Arc Air Gouging
Heavy ........... > 1/2 in (12mm) ......... 6 or 8 Light..................................................... 12
Shielded metal- Arc Welding(stick electrodes) Heavy.................................................... 14
Light ............ < 5/32 in (4mm) ........... 10 Plasma Arc Cutting
Medium ........ 5/32 - 1/4 in (4-6.4mm) 12 Light............... < 300 Amps ................ 9
Heavy ......... > 1/4 in (6.4mm) ....... 14 Medium.......... 300 - 400 Amps .......... 12
Gas Metal -Arc Welding (MIG) Heavy.......... > 400 Amps ................ 14
non - Ferrous
Base Metal .... All .......................... 11
Ferrous Base
Metal ............ All .......................... 12
___________________________________________________________________________
FUMES AND GASES CAN BE

HAZARDOUS TO YOUR HEALTH.
Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding
fumes and gases.
3. If ventilation is poor, use an approved air- supplied respirator.
4. Read the Material Safety Data Sheets and the manufacturer's instructions for
metals, consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or wear an air-supplied
respirator. Shielding gases used for welding can displace oxygen, causing
injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
7. Do not weld on coated materials, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the area is well-
ventilated, and, if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes if
welded.
___________________________________________________________________________
WELDING CAN CAUSE FIRE OR

EXPLOSION.
Sparks and spatter fly off from the welding arc. The flying sparks and hot
metal, weld spatter, hot workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding wire to metal objects can
cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within a 35 foot (10.7 meter) radius of the
welding arc. If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
5. Watch for fire. Keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
7. Do not weld on closed containers, such as tanks or drums.
8. Connect work cable to the work as close to the welding area as practical
to prevent welding current from travelling long, possibly unknown paths,
and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy shirts,
cuffless trousers, high safety shoes, and a cap.
___________________________________________________________________________
FLYING SPARKS AND HOT METAL CAN

CAUSE INJURY.
Chipping and grinding cause flying metal. As welds cool, they can throw off
slag.
1. Wear approved face shield or safety goggles. Side shields are
recommended.
2. Wear proper body protection to protect skin.
___________________________________________________________________________
CYLINDERS CAN EXPLODE IF DAMAGED.

Shielding gas cylinders contain gas under high pressure. If damaged, a
cylinder can explode. Since gas cylinders are normally a part of the weld
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to prevent the
canisters from falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings
designed for the specific application. Maintain them and associated parts in
good condition.
6. Turn face away from valve outlet when opening the cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or
connected for use.
8. Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in the Safety Standards.
________________________________________________________________________
CONSIDERATIONS ABOUT WELDING AND THE EFFECTS

NOTE: OF LOW FREQUENCY ELECTRIC AND MAGNETIC FIELDS
The following is a quotation from the General Conclusions Section of the

U.S. Congress, Office of Technology Assessment, Biological Effects of
Power Frequency Electric & Magnetic Fields – Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989):
“…there is now a very large volume of scientific findings based on

experiments at the cellular level and from studies with animals and people
which clearly establish that low frequency magnetic fields can interact with,
and produce changes in, biological systems. While most of this work is of a
very high quality, the results are complex. Current scientific understanding
does not yet allow us to interpret the evidence in a single coherent
framework. Even more frustrating, it does not yet allow us to draw definite
conclusions about questions of possible risk or to offer clear science –
based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away from your body as
practical.
5. Connect work clamp to workpiece as close to the weld as possible.
Wearers of Pacemakers:
The above procedures are among those also normally recommended for
pacemaker wearers. Consult your doctor for complete information.
PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, Safe Handling of Compressed Gases in Cylinders,
ANSI Standard Z49.1, from American Welding CGA Pamphlet P- 1, from Compressed Gas
Society, 550 N.W. Le Jeune Rd., Miami, FL 33126. Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202
Safety and Health Standards,
OSHA 29 CFR 1910, from Superintendent of Code for Safety in Welding and Cutting,
Documents, U.S. Government Printing Office, CSA Standard W117.2, from Canadian Standards
Washington, DC 20402. Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers That Safe Practices for Occupation and Educational
Have Held Hazardous Substances, Eye and Face Protection,
American Welding Society Standard AWS F4.1, ANSI Standard Z87.1, from American National
from American Welding Society, 550 N.W. Le Standards Institute, 1430 Broadway, New York, NY
Jeune Rd, Miami, FL 33126. 10018.
National Electrical Code, Cutting and Welding Processes,
NFFA Standard 70, from National Fire Protection NFPA Standard 51B, from National Fire Protection
Association, Batterymarch Park, Quincy, MA Association, Batterymarch Park, Quincy, MA
02269. 02269.
Revision History
ECR/ECN DATE REV DESCRIPTION REVISED BY APPROVED BY
1001-01 6/24/11 A Initial Release AWB AWB

1001-02 2/20/12 B Revised Wire Feed Module MEJ AWB
1001-03 4/23/12 C Revised Wire Feed Module MEJ AWB
& Drive Motor
1001-04 4/30/13 D Revised Strain Relief MEJ JC
1001-05 02/07/2014 E Revised W/F Bearings MEJ JC
1001-06 03/02/2014 F Revised Drive Bearings MEJ JC
1001-07 11/09/2015 J Revised Drive Segment BOM MEJ JC
Update Torch Braze Spec
1001-08 01/05/2016 K Updated AVC/OSC Segment MEJ
Updated Spare Parts
TABLE OF CONTENTS
PAGE
SECTION 1 - SYSTEM OVERVIEW ..................................................... 2

J- HEAD DESCRIPTION................................................................... 3
J-HEAD FUNCTIONS AND PARAMETERS ................................... 4
MANUAL TORCH ADJUSTMENTS ................................................ 5
SECTION 2 - INSTALLATION .............................................................. 6
DO'S AND DON'TS ............................................................................ 6
OPERATIONAL PRECAUTIONS ..................................................... 7
UNPACKING ..................................................................................... 9
INSPECTION ................................................................................. 9
EQUIPMENT INVENTORY .......................................................... 10
EQUIPMENT SET UP ....................................................................... 10
TRACK AND WELD HEAD MOUNTING .................................... 11
WELD HEAD CONNECTIONS..................................................... 11
WELD HEAD SET UP ................................................................... 12
SECTION 3 - CALIBRATION ................................................................ 13
3.1 TEST EQUIPMENT AND SET UP ............................................ 13
3.1.1 EQUIPMENT NEEDED ...................................................... 13
3.1.2 EQUIPMENT SET UP ......................................................... 13
3.2 WELD HEAD TRAVEL RATE ................................................... 15
3.3 MAIN WIRE FEED RATE .......................................................... 16
3.5 MAIN OSCILLATOR .................................................................. 18
3.5.1 ELECTRO-MECHANICAL CENTERING .......................... 18
3.7 J-HEAD CALIBRATION DATA SHEETS ................................. 20
SECTION 4 - WELDING ........................................................................ 21
SECTION 5 - MAINTENANCE.............................................................. 23
ROUTINE MAINTENANCE ............................................................. 23
WELD HEAD TROUBLESHOOTING GUIDE................................. 25
SECTION 6- SPARES ............................................................................ 27
LEVEL ONE ....................................................................................... 28
LEVEL TWO....................................................................................... 28
LEVEL THREE .................................................................................. 29
APPENDIX - DRAWING PACKAGE ..................................................... 30
Operations and Maintenance Manual 315-4110-901

1
SECTION 1 - SYSTEM OVERVIEW
The GT VI/P300/P300 System is available with an assortment of standard
weld heads, -F Head, -G Head, -Block Head, ID Head, J Head and FFIP
Head. This User Documentation Package includes information on the Model
“J” Weld Head. For discussion purposes, a GT VI/P300/P300 System will
consist of the following:
1. A GT VI/P300/P300 Power Supply
2. A Remote Pendant
3. A Weld Head (like a J Head) and appropriate Tracks
4. Any Optional Extension Cable Sets
5. Any Optional Remote Viewing or Data Acquisition Subsystem
Fuse & Jumper Settings
Axis External FuseValue DSB Jumper Setting LDC Part Number
Travel 0.5A Fast Blow 1.0A AGC1/2
Oscillation 0.75A Slow Blow 2.0A 827-0001-007
AVC 0.5A Slow Blow 1.0A MDL-0.5
Wire Feed 1.5A Slow Blow 2.0A MDL-1.5A

(75 ipm)

2
J-HEAD DESCRIPTION
The J-Head is a special configuration head, to provide low radial clearance. The
drive segment features the patented Liburdi Dimetrics Track Propulsion Drive
System, where a Travel Drive DC PM Motor/Gearbox is coupled to a pair of knurled
nylon drive rollers that engage the knurled track or pipe surface. The drive rollers
are loaded against the track by the clamping chain that wraps around the track or
pipe. The Travel Drive is capable of programmed Travel rates of up to 20 IPM.
A DC PM motor drives the Main Oscillator Slide Assembly which is mounted in the
AVC/OSC segment. To provide maximum durability and rigidity for the Oscillator
Ram, the Oscillator Slide uses a lead screw coupled to a set of dual rails, and a
precision linear potentiometer provides feedback of the Main Oscillator Slide's
absolute position.
The AVC Mechanism is mounted to the front end of the Oscillator guide rod: This
mechanism provides an arced AVC stroke. This is powered by a DC PM Motor, and
utilizes a direct gear drive off of the AVC motor output shaft. The AVC also has
limit switches to protect the drive from running into the limits, so no damage can
occur from excess travel.
The Front End Assembly contains the following elements:
¾ A Torch Assembly
¾ A Wire Manipulator with manual up/down and in/out wire adjustment
The Main Wire Feeder is designed to produce wire rates up to 75 Inches per Minute
and is driven by a DC PM Gearmotor. Again to provide the ability to minimize
radial clearance, the Main Wire Spool is also attached to the Skate by a pivoting
bracket. It holds a two or can hold a four inch wire spool, with an adjustable drag
brake.

3
J-HEAD FEATURES
¾ DC Drive 75 IPM Main Wire Feed Motor

¾ DC Drive Torch Oscillator
¾ DC Drive AVC Motor
¾ DC Drive 20 IPM Travel Motor
¾ 2” or 4” Main Wire Spool
¾ Torch Assembly
J-HEAD FUNCTIONS AND PARAMETERS

TRAVEL Rate is 0 to 20.0 IPM in the forward or reverse direction:
MAIN WIRE FEED Rate is 0 to 75 IPM with a maximum jog feed/retract rate of 75
IPM.
AVC Stroke or travel is .75” Inches with the small AVC module. The Torch
Assembly can be adjusted on the oscillator shaft to get more or less stroke where
needed.
MAIN Oscillator Widths (Amplitude) are programmable.
Note: There are physical limits on some combinations of parameters for the Main
(Torch) Oscillator. For example, not all combinations of Oscillation Width
and Excursion Time are achievable: With programmed Width and Excursion
settings of 0.75 inches and 0.1 seconds, respectively, the required slew rate
would be an unattainable (0.75 inches)/(0.1 sec) x 60 sec/min = 450
inches/minute. Main or Torch Oscillator cross seam or centerline adjustment
range is +/- .38 Inches.

4
MANUAL TORCH ADJUSTMENTS
Torch Lead/Lag
Torch Vertical Location
Main Wire Vertical and Cross Seam
The Weld Head Control and Service Cable Length is 35 feet, and the
operating radius may be extended to 235 feet, if appropriate extension cables are
used.

5
SECTION 2 - INSTALLATION
WARNING!
Before applying system power, it is very important to take time for the
following:
1. If this is the first time power will be applied to the system, or if the system
has been moved or reconfigured in any way, carefully follow the
Installation Instructions given in "System Installation" section of the
Gold Track VI/P300 Maintenance Manual, Failure to follow these
instruction may result in serious equipment damage. The information
provided describes how to receive and inspect the equipment, how to properly
configure and interconnect all of the components, and how to turn the GT
VI/P300 or P300 System ON and OFF.
2. Become familiar with equipment operation and operating instructions by

reading all the manuals provided: be sure to pay special attention and follow
all DANGER, CAUTION, WARNING, and special NOTES.
3. Review all SAFETY information provided at the front of this J WELD

HEAD OPERATIONS AND MAINTENANCE MANUAL.
4. Review the following DO's and DON'Ts and OPERATIONAL

PRECAUTIONS.
DO'S AND DON'TS

The following recommendations are offered as an aid to the customer in maintaining
smooth running, fully operational Weld Heads. Liburdi Dimetrics Weld Heads are
dependable and will last a long time without repair, but they are close tolerance,
precision machines which require proper care and maintenance.
Do not run Oscillator Mechanisms into stops or against anything else.

Do not run the head on misaligned track.
Do not run the AVC Slide into the stops or jam the Torch against the Work.
Do not force anything that does not move freely. If something is binding, locate the cause.
Do not use acid or related products, on or near the weld head.

6
Do not leave the head in a wet or damp area.
Do not leave the head dirty. It should be cleaned thoroughly after each use.
Do not use oil or any other substance on the head.
Do not weld without factory approved coolants.
Do use factory provided accessories and parts.
Do not use cabling, torch, or front end components to pick up the weld head.
Do maintain proper sleeving on all the cables.
Do not disassemble the head unless you have had factory instruction.
Do not operate the system without a good ground.
Do position the track securely on the pipe to be welded.
Do not let the head cable come in contact with hot pipe (Weld area).
Do insure that the track is centered on the pipe so that the cam rollers clear the pipe surface.
Do make sure the set screws are below the surface of the track when the track is mounted.
Do not operate without correctly installed tungsten, collet, or other torch components.
Do not allow the welding wire to become kinked
Do not put the wire nozzle so close to the torch that it will be in the Arc.
Do not interchange weld heads or GT VI/P300 power sources without spot checking calibration.
Do not operate the head if the audible interlock alarm is ON.
Do not use the Torch Oscillator if the mechanism exhibits excessive mechanical play or backlash.
Do not operate the AVC Servo if the mechanism exhibits excessive mechanical play or backlash.
OPERATIONAL PRECAUTIONS
The items listed in the following paragraphs should be checked on a regular basis to
prevent some of the more common problems encountered while welding.
¾ GROUNDING
Fasten all ground connections securely with clean terminals and clamps.
¾ INPUT POWER
The input power cable should be kept away from all walkways and heavy
equipment travel paths to prevent damage of the cable and the system.

7
¾ GAS FITTINGS
All gas fittings must be kept free of oil, moisture, dust, and grease. A tight
seal must be maintained to prevent contamination of the weld.
¾ WATER FITTINGS
Check these lines and fittings for leakage periodically.
¾ TORCH
The torch should be inspected for tightness of water lines and power connections.
Insure torch components are properly sized and properly secured; i.e. collet,
tungsten, gas lenses, cups, etc. The torch body should be at 90 Degrees to the work
being welded.
¾ COLLET
Insure the torch collet matches the tungsten size; also insure the collet
tightly grips the tungsten. A loose collet will result in hard Arc starts, gas
turbulence at the electrode, and incorrect arc length.
¾ TUNGSTEN
The tungsten must be free of oxides and contamination and have proper tip
geometry. The Arc will transfer erratically or not at all if these conditions
are not met.
¾ GAS LENSES
The torch gas lens should be free of splatter and contamination for maximum
gas flow efficiency and proper gas shielding.
¾ WIRE FEED DRIVE

The wire feed drive mechanism should be cleaned frequently to remove dust
and abrasive wear particles. Use CLEAN, DRY AIR OR NITROGEN to blow
the particles out of the feed lines, nozzle, drive rollers and gear drive
mechanism. The tension should be sufficient to prevent slippage when being
held back by hand pressure or with wire cutting pliers.
CAUTION: Always bend the wire over into a loop to prevent puncturing
the hand while making this adjustment, or use pliers.
¾ WIRE ENTRY NOZZLE

The Wire Entry Nozzle should be adjusted for proper distance between it and
the tungsten before starting the weld sequence. The wire nozzle used must
be the appropriate size for the wire being used to prevent the wire from
oscillating upon entering the Arc.
¾ SPOOL TENSION
8
Tighten the lock nut on the wire spool hub sufficiently to prevent the wire
from unwinding off the spool but not so tight as to unnecessarily load down
the drive mechanism.
¾ TRACK ALIGNMENT
Track alignment is done with the Ball Allen Driver tool supplied with the
unit. Align the track as close as possible to insure equal clearance around
the circumference of the pipe being welded. In cases where the head is used
in direct drive with the surface of the tube/pipe, simply drive the oscillator to
the center of its stroke, and apply the head directly to the tube/pipe surface.
Do this by aligning the torch in the center of the joint to be welded and clamp
the latching chain.
¾ MOUNTING THE HEAD

Handle the weld head carefully. Do not transport the weld head by the cable,
cable connector, torch, or other front end components. When mounting the
weld head onto the track, lower the head carefully to straddle the track while
at the same time holding the clamping chain and clamp. Wrap the head
around the track or pipe and latch the chain into its catch. Then fold the
spring locking handle down until it snaps into position. It does not take a
great deal of force to lock the head in place. If the clamp chain is too tight,
the head may bind on the track and not rotate. Be sure not to overtighten the
chain. A light pressure on the spring loaded locking clamp is all that is
needed. Operate the TRAVEL JOG function to see that there is no slippage or
binding. The threaded screw in the locking handle can be adjusted to add or
take out slack in the chain locking mechanism.
UNPACKING
Liburdi Dimetrics has packaged this equipment using the best materials and
proven shipping methods. Once the shipment departs Liburdi Dimetrics, all
responsibility is transferred to the freight company for the safe delivery of
equipment to its destination.
INSPECTION
Upon delivery, the receiver must inspect the shipping container and note any
externally visible damage on the freight bill.
If the shipping container appears to be excessively damaged, DO NOT UNPACK;

instead, notify the FREIGHT COMPANY immediately.

9
After a thorough visual inspection of the shipping container's exterior, place the
equipment in the general area where it will be used. Then open the gray, reusable,
shipping container.
Carefully remove the J-Head from the shipping container: do not lift or transport
the head by the cable, cable connector, torch, or other front end components. The
weld cable is attached to the J-Head and is packaged underneath the head. It may
require more than one person to remove the head and cable without damaging the
Weld Head.
Thoroughly inspect the weld head and accessories (externally and internally) for
any concealed damage.
Contact Liburdi Dimetrics immediately if the equipment has sustained concealed

shipping damage. The freight company will be called to inspect the package and
equipment before any claim may be settled on our part.
EQUIPMENT INVENTORY
Inventory and organize all items on the shipping manifest and the ship-kit,
including the User Documentation Package, to ascertain that all of the items have
been received and are in good condition.
If there is a shortage or problem,

Notify CUSTOMER SERVICE at
(1-704-230-2510) or (1-800-991-2100)
EQUIPMENT SET UP
The Track mounting procedure described here covers the mounting of circular
Track on pipe or cylindrically shaped parts.
IMPORTANT: The AVC Servo relies on remote Arc Voltage sensing

through wiring connected to the weld head frame. Therefore, the weld head
and track must make electrical connection to the work piece for proper servo
operation.
A wire (a Work Sense wire) must be connected externally between the Track
and the work piece for applications where the Track does not make direct
electrical connection to the work piece through the mounting structure. To
avoid voltage sensing errors, do not connect the Work Sense wire to the same
point as the high current Work Cable.

10
TRACK & WELD HEAD MOUNTING
Separate the circular Track into two halves by simply slipping the two sections
apart. Retract the mounting screws from the pipe surface. Then mount and re-
assemble the two Track halves on the pipe to be welded.
Align the Track with the weld joint in a position which will insure that the Torch
will be nearly centered on the weld joint when mounted on the Track with the Main
Oscillator slide roughly centered.
Next screw the Track locking screws down evenly until the Track is secured on the
pipe. In order to guarantee good electrical connection, make sure that the feet are
touching bare metal.
Wrap the head around the track or pipe and latch the chain into its catch. Then fold
the spring locking handle down until it snaps into position. It does not take a great
deal of force to lock the head in place. If the clamp chain is too tight, the head may
bind on the track and not rotate. Be sure not to overtighten the chain. A light
pressure on the spring loaded locking clamp is all that is needed. Operate the
TRAVEL JOG function to see that there is no slippage or binding. The threaded
screw in the locking handle can be adjusted to add or take out slack in the chain
locking mechanism.
At some point after Initial turn-on, jog the Weld Head TRAVEL FWD and REV
several times and re-check the clamping chain tension: there should be no slippage
or binding. If necessary, tighten snugly with an Ball Allen Driver, taking care not
to over tighten.
NOTE: Always re-check the clamping chain tension after mounting or re-
mounting the Weld Head to the Track.
WELD HEAD CONNECTIONS
Connect the Weld Head cables to the GT VI/P300/P300 Connect Panel as follows:
¾ Connect the Weld Head Control cable to the 61 pin WELD HEAD Control connector
(PTJ2) on the Connect Panel.
¾ Connect the Weld Head Gas line to the GAS OUT fitting on the Connect Panel.
¾ Connect the backup gas if needed to the second GAS OUT fitting on the Connect
Panel.

11
¾ Connect the Weld Head Water Lines to the WATER INPUT and WATER OUT
fittings on the Connect Panel.
¾ Connect the Weld Head Electrode cable to the ELECTRODE connector on the
Connect Panel.
Also insure that the part to be welded is properly connected to the WORK connector
on the Connect Panel and that all other connections to the GT VI/P300/P300 are
properly configured: refer to the GT VI/P300/P300 manuals, if needed.
WELD HEAD SET UP
¾ Ensure that the cables do not bind the Weld Head movement and that proper
clearances are maintained.
¾ Insure that the Torch Front End is installed on the AVC Assembly on the G Head.
¾ Install the Wire Spool and thread the wire through the liner, drive rolls, and wire
nozzle. Use the wire jog to check the wire feeder: adjust drive roll and spool tension
as required.
¾ Adjust tungsten and Main Wire Feed nozzle per the Welding Procedure to be used.
¾ Use the Jog switches and Oscillator Centering controls to spot check the
performance of the AVC, Travel, and Main Oscillator mechanisms.

12
SECTION 3 - CALIBRATION
3.1 TEST EQUIPMENT AND SET UP
3.1.1 EQUIPMENT NEEDED
J-Head
Welding Wire on two or four inch spools
1 ea. Weld Head Track of suitable size
1 ea. Pipe of suitable size
1 ea. Pipe Stand or other pipe support
1 ea. Tape Measure
1 ea. Stop Watch
1 ea. 4 1/2 Digit DVM
1 ea. Caliper (Range = 0 to 5" or more, Resolution = 0.001" or better
1 ea. GT VI/P300 Welding Power Source
1 ea. Remote Terminal or Pendant
3.1.2 EQUIPMENT SET UP
3.1.2.1 If not already done, connect the weld head and set up the equipment as
described under the section entitled, "EQUIPMENT SET UP," in Section
2 of this manual.
3.1.2.2 Apply GT VI/P300 System Power, and initially program the following
screens as shown: If needed, refer to the Gold Track VI Operations
Manual.

13
SET UP SCREEN - INITIAL SETTINGS
Set the WELD HEAD parameter to J-Head; and set the WIRE STOP
DLY, and WIRE PULLBACK parameters all equal to ZERO.
HEADER SCREEN - INITIAL SETTINGS:
SCHED: #### TOTAL SEGMENTS= 1

INIT ARC GAP= 50 WIRE UPSLOPE= .0
PRE PURGE= 1 POST PURGE= 1
TRAVEL DELAY= .0 DOWN SLOPE= .0
WIRE DELAY= .0
AVC RESP= 40 AVC SLOW BAND= .4
-------------------MODES------------------
SEGS: TIMED CHAIN= DIR: F
SEGMENT 1 SCREEN - INITIAL SETTINGS:
SCHED:#### SEG= 1/ 1 TIME= 60.0

PRI | BKG | SLOPE= .0
CURRENT= 0.0 | 0.0 | OSC WIDTH= .00
VOLTAGE= 0.0 | 0.0 | IN DWELL= 2.50
WIRE= 60.0 | 60.0 | EXCURSION= 1.00
TRAV IPM= 10.0 | 10.0 | OUT DWELL= 2.50
AVC MODE= CONT PULSE (MODE)= OFF
3.1.2.3 Use the WIRE (Main) ON/OFF button on the Remote Terminal to turn
the wire feeder OFF.
3.1.2.4 Insure the GT VI/P300 is in the TEST Mode before proceeding.

14
3.2 WELD HEAD TRAVEL RATE
3.2.1 Find a convenient reference point on the Weld Head which is close to the
drive surface (knurled surface) at an outer edge of the track. This point
on the Weld Head will be called the "Weld Head Reference Point."
Make a mark on the outer edge of the track drive surface which is
adjacent to and in line with the Weld Head Reference Point. Label
this mark "0." Then measure off and mark 10 one inch increments in the
forward direction and 10 one inch increments in the reverse direction at
similar locations along the outer edge of the drive surface.
Label the marks on the forward side "+1" through "+10," starting with
"+1" for the mark next to "0." Similarly label the marks on the reverse
side "-1" through "-10," starting with "-1" for the mark next to "0." These
marks will be used to gauge the correct Travel speed.
3.2.2 Use the TRAVEL jog buttons on the Remote Terminal to align the head
reference point with the 0 Inch Mark.
3.2.3 Insure the system is in the TEST mode and that the wire feeder is turned
OFF; then press the START Button. To verify proper GT VI/P300
operation and timing accuracy, use the Stop Watch to check the actual
Weld Head Travel Time. The Travel Time should be 60 +/- 0.3 Seconds,
and the total travel distance should be (s/b) 10 +/- 0.2 Inches. Record the
Stop Watch Time on the Calibration Data Sheet.
3.2.4. If necessary, adjust Pot P1 (inside the weld head connector), and repeat
Steps 3.2.2 through 3.2.4 until the tolerance given is met without need for
further adjustment. Lightly pencil in the final travel distance reading on
the Calibration Data Sheet: subsequent measurements may require the
initially recorded data to be revised.
3.2.5.1.1. Once the travel speed is close to the commanded value by adjusting the
upper travel speed pot P1, now test the low speed calibration. Reset the
Travel jog speed from 10 IPM to 1 IPM. Run the same test for 60 seconds
at the 1 IPM speed. Adjust pot P2 in the weldhead connector until the
weldhead lines up with the 1 inch mark during travel speed testing.
These two pots interact with each other, so now the upper speed must be
re checked. Repeat the procedure in steps in 3.2.3 through 3.2.5 until no
further adjustment is needed for both the upper and lower travel speeds.
Once these two speeds are set, simple software calibration within the GT
IV or P300 will keep the weldheads travel speed accurate.

15
3.4 WIRE FEED RATE (75 IPM Motor)
3.4.1 Use the weld schedule screen settings given in 3.1.2.2 above, set the 1ST
SEGMENT PRI and BKG TRAV speed settings to 0.0 IPM. Insure the
1ST SEGMENT TIME is 60.0 Seconds.
3.4.2 Use the TRAVEL Jogs to move the weld head to a convenient test
location, and use the WIRE ON/OFF button on the Remote Terminal to
turn the Wire Feeder ON.
3.4.3 If not already done, install the Wire Spool and thread the wire through
the liners, drive rolls, and wire nozzle. Adjust drive roll and spool tension
as required, and insure the wire runs freely when jogged.
3.4.4 To remove slack (in the FEED Direction) in the wire liner, jog the Wire in
the FEED direction; then cut the wire flush at the end of the nozzle.
3.4.5 Insure the system is in the TEST mode; then press the START button.
To verify proper GT VI/P300 operation and timing accuracy, use the Stop
Watch to check the actual Wire Feed time. Also note that the wire does
not pull back at the end of the sequence. The Wire Feed time should be 60
+/- 0.3 Seconds. Record the Stop Watch Time on the Calibration Data
Sheet.
After the sequence is completed, measure the amount of wire that was fed
through the nozzle: s/b 60 +/- .50 Inches.
3.4.6 If necessary, adjust Pot P3 inside the weld head connector and repeat
steps 3.4.4 through 3.4.6 until the tolerances given are met without need
for further adjustments. Lightly pencil in the final value for the amount
of wire fed on the Calibration Data Sheet: subsequent measurements may
require these steps to be repeated, requiring the recorded data to be
revised.
3.4.7 Access the 1ST SEGMENT SCREEN and change the PRI and BKG
WIRE settings to 10 IPM.
3.4.8 To again remove slack (in the FEED Direction) in the wire liner, jog the
Wire in the FEED direction; then cut the wire flush at the end of the wire
nozzle.
3.4.9 Press the START button, and after the sequence is completed, measure
the amount of wire that was fed through the nozzle. s/b 10 +/- 0.2 Inches.

16
3.4.10 If necessary, adjust Pot P4 inside the weld head, and repeat steps 3.4.8
through 3.4.10 until the amount of wire fed meets the tolerance given
without need for further adjustments. Lightly pencil in the final value for
the amount of wire fed on the Calibration Data Sheet: subsequent
measurements may require these steps to be repeated, requiring the
recorded data to be revised.
3.4.11 Pots P3 and P4 interact; therefore, access the 1ST SEGMENT SCREEN
and set the PRI and BKG WIRE Speeds back to 100.0 IPM. Then repeat
Steps 3.4.4 through 3.4.11 until all the applicable tolerances given are met
without need for further adjustment of either potentiometer.
Once these two speeds are set, simple software calibration within the GT
IV or P300 will keep the weldheads travel speed accurate.
3.4.12 Using the method outlined in Steps 3.4.4 and 3.4.5 as a guide, measure
and record (lightly pencil in on the Calibration Data Sheet) the amount of
wire fed for the following 1ST SEGMENT PRI and BKG WIRE speed
settings: 25.0, 50.0, and 75.0 IPM.
When finished, use the WIRE ON/OFF button on the Remote Terminal to
turn the Wire Feeder OFF; and finalize (darken) the final readings on the
Calibration Sheet.

17
3.5 MAIN OSCILLATOR
For this section, set the screens and controls as specified in 3.1.2.2
through 3.1.2.4, except set the 1ST SEGMENT PRI and BKG TRAV
speed settings to 0.0 IPM. Also access the HEADER SCREEN and
change the SEGS Mode to MANUAL.
3.5.1 ELECTRO-MECHANICAL CENTERING
Some small amount of "hunting" is normal; therefore, in performing the

following steps it may be necessary to average the DVM and caliper
reading.
3.5.1.1 The Main Oscillator electro-mechanical centering is calibrated at the

factory. Improper adjustment can result in mechanism failure; therefore
field adjustment is not recommended. However, if the electro-mechanical
center requires re-calibration or if Main Oscillator mechanical
components are replaced in the field, use the procedure below to re-
calibrate the electro-mechanical centering.
WHEN IN DOUBT
CALL LIBURDI DIMETRICS CUSTOMER SERVICE AT
1-800-533-9353 OR (704)-230-2510.
3.5.1.2 Use a caliper and the Remote Terminal to move the Main Oscillator slide
mechanism to the center of mechanical travel (Zero Center Position) to
within 0.01 or 0.005 Inches, if possible.
3.5.1.3 Temporarily remove the Main OSCILLATOR MOTOR DRIVE Fuse;

and while performing the next few steps, and disconnect the weldhead
from the GT6. Be very careful not to disturb the slide's Zero Center
position.
3.5.1.4 Use a DVM set for 20 k ohm setting for the next step. Connect the meter
leads across the leads of the feedback pot.
3.5.1.5 Remove the cover protecting the AVC/Oscillator Segment Next loosen the
set screw that holds the end of the pot shaft in to the coupling. Carefully
adjust the pot shaft until DVM reading is 5.00k ohm. Then carefully
tighten the screw and coupling while insuring the DVM reading stays
within the tolerance given.

18
3.5.1.6 Re-install the Main OSCILLATOR MOTOR DRIVE Fuse; and reconnect
the weldhead. Use the Remote Terminal to again move the Main
Oscillator slide for the full range of oscillator motion. Take care not to run
into the hard stops.
Then check the slide position, it should be within 0.02 Inches of the
mechanical center. If not, the Main Osc Slide's Zero Center Position was
probably disturbed during the alignment; in this case, repeat Steps 3.5.1.2
through 3.5.1.6. If the steps in this section were performed, check off the
"Main Osc Electro-mechanical Alignment Performed" line on the
Calibration Data Sheet.

19
3.7 J-HEAD CALIBRATION DATA SHEETS
Please Print:
Test Date(s): ________________________ Technician(s):_______________________
GT VI/P300 S/N: _________________________
Weld Head S/N: _____________________
3.2 WELD HEAD TRAVEL
3.2.3 Stop Watch Time ________________ Seconds; s/b 60.0 +/ 0.3 Seconds
3.2.4 10.0 IPM Travel Distance ________________ Inches; s/b 10.0 +/- 0.4 Inches
3.2.5 1 IPM Travel Distance ________________ Inches; s/b 1.0 +/- 0.08 Inches
3.3 MAIN WIRE FEED
3.3.5 Stop Watch Time ________________ Seconds; s/b 60.0 +/ 0.3 Seconds
3.3.6 75 IPM Wire Feed ________________ Inches; s/b 100 +/- 2.0 Inches
3.3.8 25 IPM Wire Feed ________________ Inches;s/b 25 +/- .05 Inches
3.5 MAIN OSCILLATOR
3.5.1 ELECTRO-MECHANICAL CENTERING
3.5.1.6 Main Osc Electro-mechanical Alignment Performed? YES NO
3.5.2 MAIN OSC WIDTH AND CROSS SEAM RANGE
3.5.2.1 Main Osc Total Mechanical (Slide) Travel ________________ Inches
3.5.2.4 Center to Front End ________________ Inches
3.5.2.5 Center to Back End ________________ Inches

20
SECTION 4 - WELDING
WARNING!
Please observe the WARNING given at the beginning of Section 2 of this manual.
In particular, take time to review the DO's and DON'Ts and OPERATIONAL
PRECAUTIONS provided in Section 2.
Prepare the J-HEAD for welding as follows:
4.1 Refer to "SECTION 2 - INSTALLATION" for track mounting, weld head

installation, and weld head set up instructions. Then mount the track and
weld head onto the part to be welded.
4.2 Adjust the tungsten electrode as defined in the Welding Procedure;

otherwise, adjust it so that it projects approximately 0.5" from the weld cup
lip.
4.3 Use the Remote Terminal TRAVEL jog and Main Oscillator Jog to position
the tungsten over the weld groove prep area at the desired starting location.
4.4 Adjust the positions of the Wire Entry Nozzle per the Welding Procedure. In
general, do not place the nozzle so close that they will be melted by the arc or
so far away that wire cast causes the entry point to deviate excessively.
4.6 Use the wire manipulator manual cross seam adjustments to center the wire
nozzle on the tungsten.
4.7 Use the wire manipulator manual vertical adjustments to position the wire
entry point per the Welding procedure. Otherwise initially adjust the nozzle
such that jogging the wire will cause the wire to pass about 0.06 Inches below
the tungsten.
Note: The wire entry point is a critical parameter and should be optimized
on a case-by-case basis during weld development.
4.8 Use the Remote Terminal to jog the wire to the desired starting positions at
the end of the wire nozzle.

21
4.9 Use the Remote Terminal to slowly jog the AVC DOWN until it just touches
the pipe, then jog the AVC UP 0.75 Inches.
NOTE: BE CAREFUL not to jam the tungsten or AVC into the pipe, it
could damage the AVC mechanism or motor.
4.10 Loosen the screws on the AVC Front End and move the Torch to a lower
position such that it comes closest to touching the pipe. Tighten the screws
to secure Torch in this new position.
4.11 Load or program a Weld Schedule into the Gold Track VI Power Supply per
Welding Procedure. See the "SAMPLE SCHEDULE" section of the GOLD
TRACK VI OPERATIONS MANUAL.
4.12 Activate the WELD mode.
The GT VI/P300 and J-Head are now ready for welding.

22
SECTION 5 - MAINTENANCE
ROUTINE MAINTENANCE
The J-Head requires high temp grease on the AVC/OSC gearing internal to the
AVC/OSC segment housing. Re-calibration is required only when welds are not
satisfactory. However, to conform to industry standards, it is suggested that re-
calibration occur every three months.
Perform the following at the intervals indicated:
¾ Wire feed problems are very common; therefore, the wire nozzles, guides, and
liners should be very frequently cleaned and inspected for debris or excessive
wear. Wire drive roll and spool tensions should also be checked every time
the wire spool is changed.
¾ Each time a tungsten, gas cup, diffuser, orifice, or any torch component is
changed or reconfigured in any way, insure all of the torch components are
correctly sized, assembled, and tightly secured.
Perform the following at least once each week:
¾ Inspect all Weld Head cables and hoses: repair any damage before it stops
welding operations.
¾ Check all connectors. If dirty, clean with dry compressed air, argon or
nitrogen.
¾ Check for positive mating on all connectors.
¾ Check gas and water fittings and flow paths: insure hoses are not crimped
and that fittings are tight.
¾ Inspect torch body and insulators for any damage. Repair any damage.
¾ Check the AVC and Oscillator Slide Mechanisms for excessive play.
¾ Check and tighten any screws or hardware that has become loose.
¾ Inspect and replace any knurled travel drive roller which has become
excessively worn.

23
¾ Insure the head fits snugly on the track: inspect and replace any excessively
worn drive rollers. Check the steel guide rollers as well, as these rollers
engage the sides of the track to prevent the head from canting or moving
from side to side.
¾ Inspect the clamping chain and clamp: replace any bent or severely worn
components.
CAUTION!
Do not place the Weld Head cable on hot pipe or plate: Drape it away
from or provide external support to keep it away from the weld joint or any
preheated weldment. If possible, hang the cable, route it away from traffic
areas, or use other means to protect it from being crushed by heavy objects
such as a fork lift.

24
WELD HEAD TROUBLESHOOTING GUIDE
PROBLEM POSSIBLE CAUSE SOLUTION

TUNGSTEN
ARC WILL NOT STRIKE REGRIND OR TIGHTEN
CONTAMINATED OR LOOSE
BAD WORK OR ELECTRODE

ARC WILL NOT STRIKE FIND & FIX
CONNECTION
INITIAL AMPS TOO LOW
INCREASE INITIAL AMPS
ARC STRIKES & GOES OUT FOR TUNGSTEN/GAS
OR REGRIND TUNGSTEN
COMBINATION
SEGMENT 1 VOLTAGE TOO
ARC STRIKES & STUBS OUT INCREASE VOLTAGE
LOW
INITIAL ARC GAP SET TOO

ARC STRIKES & STUBS OUT INCREASE SETTING
LOW
ARC STRIKES & STUBS OUT TUNGSTEN IS BLUE AFTER FIND AND FIX A GAS LEAK
OR AVC ACTION ERRATIC WELDING OR CONTAMINATION
EXCESS SLOP IN AVC SLIDE DISASSEMBLE AVC, SLIDE

AVC ACTION ERRATIC
(>.032”) & ADJUST MINIMIZE PLAY
CLEAN OUT LINERS, WIRE

NOZZLES; ADJUST DRIVE
MAIN WIRE SLIPPING OR
WELD TOO HOT ROLL OR SPOOL TENSION,
STALLING
ADJUST ENTRY ANGLE,
CHECK WIRE CALIBRATION
CHECK CAM ROLLER

WELD TOO HOT OR COLD TRAVEL SPEED WRONG TENSION; CHECK TRAVEL
SPEED CALIBRATION
CHECK WELD FILE FOR

CURRENT OR VOLTAGE PROPER VALUES; CHECK
WELD TOO HOT OR COLD
WRONG POWER SUPPLY
CALIBRATION
DISASSEMBLE SLIDE &

OSCILLATOR TOO SLOPPY EXCESS SLOP IN SLIDE
ADJUST TO MINIMIZE PLAY

25
REMOVE MOTOR FUSE ON
POWER SUPPLY: POWER UP
OSCILLATOR RUNAWAY BROKEN FEEDBACK LOOP & CHECK +/- 10V
REFERENCE & POT
FEEDBACK
CHECK GAS BOTTLE,

VALVE, ETC. CHECK & FIX
ANY KINKS OR
GAS FLOW FAULTS GAS FLOW OBSTRUCTION
OBSTRUCTIONS IN BOTH
THE CENTER & SHEILD
FLOW SYSTEMS
CHECK & FIX ANY KINKS

OR OBSTRUCTIONS IN THE
COOLANT FLOW WATER FLOW SYSTEM;
COOLANT FLOW FAULTS
OBSTRUCTION CHECK THE FILTER ON THE
COOLANT PUMP & CLEAN
IF NEEDED

26
SECTION 6- SPARES

27
J HEAD SPARE PARTS, CONSUMABLES "REV C"
PART NUMBER: J HEAD SPARES, LEVEL 1
Ref Des Item Number Qty Item Description

0001 315-4105-007 4 WIRE NOZZLE, .035 WR
0002 315-4005-044-2 2 A013786 COLLET,ELECTRODE 3/32
0003 315-4105-068 6 GAS CUP,PYREX,DLP
0004 315-4105-004 4 WIRE NOZZLE, .030 WR
0005 9464K21 2 A013776 O RING,VITON,9/16X11/16
0006 315-4105-118 4 GAS LENS ASSY, J HEAD
0007 98408A126 6 A013808 RG, RET, E, 3/16
0008 315-4005-046 2 TUNGSTEN,ELEC,.093X1.188,J HEAD (PKG. OF 10 PCS)
0009 315-4105-116 2 BACK CAP ASSEMBLY,DLP TORCH
J HEAD SPARE PARTS, NORMAL WEAR, "REV E"

0002 A 7Y 5M PSS1006 4 BEARING, BALL, 6MM BORE X 10MM OD, 440C SS
0003 315-4002-004 4 A013489 DRIVE ROLLER,HARD,DLP
0004 315-4113-010 1 GEAR, WIRE DRIVE, J HEAD
0005 315-4103-106 4 FITTING ASS'Y, J-HEAD WIRE LINER
0006 315-4112-110 2 WIRE LINER, 7.5"
0007 315-4112-111 2 WIRE LINER, 5.5"
0008 52545K38 3 CLAMP,STEPLESS EAR,.25"OD HOSE
0009 827-0001-007 2 A013809 FUSE ,SLO-BLO,3/4AMP
0010 AGC1/2 2 FUSE AGC 1/2 AMP
0011 851-0609-011 2 PIN, DOWEL, .0602 X .219LG
0012 93740A175 2 PIN,SPRING,COILED,3/32X3/8LG,SS
0013 315-4101-113 4 ROLLER ASSY, GUIDE, J HEAD
0014 851-0911-050 2 A013812 PN,ROLL,3/32X1/2 SS
0015 98408A116 2 A013807 RG, RET, E, 3/32
0016 98408A126 2 A013808 RG, RET, E, 3/16
0017 MDL-3 2 A013296 F,3AMP,SLO-BLO,32V
0018 315-4006-120 2 ROLLER ASSEMBLY,DLP CHAIN
0020 164-9000-2306 2 NUT, BRASS
0021 98407A132 2 RING,RET,E-CLIP,5/16 SHAFT
0022 315-4113-105 2 ROLLER ASSEMBLY, IDLER, W/F, J HEAD
0023 S7220Y-09914 2 PIN, SPRING, COILED, .093 X 7/16, SS
0024 6391K171 2 BRG, SLV, 3/8X 1/2X 1/4
0025 S9912Y-G1225FS2G 2 BEARING, BALL, FLANGED, .125 BORE
0029 MBG6-4 2 BEARING,BALL,SHIELDED, 5MM BORE,16MM OD, 5MM WIDE
0030 315-4113-012 2 ROLLER, WIRE DRIVE, J HEAD
J HEAD SPARE PARTS, REPAIRS "REV E"

0001 315-4105-101 1 TORCH ASSEMBLY
0002 315-0001-101 1 TOOL KIT, J-HEAD
0003 315-4101-110 1 PINION ASS'Y,DLP AVC
0004 315-4122-105 1 DRIVE MOTOR ASSY,EXTENDED,SQ,J HEAD
0005 315-4113-102 1 WIRE FEED ASSEMBLY, J HEAD
0006 315-4113-104 1 WIRE DRIVE MOTOR ASSEMBLY, J HEAD
0007 315-4008-106-1 2 TIG LINE ASSY, J-HEAD
0008 315-4008-111 2 HOSE ASSY,GAS,J HEAD TO HOT BLOCK
0010 851-1314-050 2 A013290 PN,DWL, 1/8 X 1/2
0011 851-1314-075 2 A013291 PN,DOWEL, 1/8 X 3/4,SS
0014 851-1314-125 2 A013294 PN, DOWEL, 1/8X1 1/4
0015 863-1008-083 4 A014047 S,CH,SD,4-40X3/16,SS
0016 92085A224 2 A013800 KIT,SHCS ASSORTMENT,1300 PCS
0017 92145A212 2 A013801 KIT,BHCS ASSORTMENT,300 PCS
0018 9713K54 10 SPRING,BELVILLE,1/8ID X 1/4OD
0019 FIT-105-3/16 4 A013813 SLEEVE, SHRINK, 3/16 ID
0020 315-4101-104 1 OSC MOTOR ASSY, J HEAD
0021 5903-0012-3 1 LINEAR POT,5K PRECISION
0022 315-4101-115 2 LIMIT SWITCH ASSY, AVC, J HEAD
0023 315-4101-022 1 MOTOR,MODIFIED,DLP AVC
APPENDIX
DRAWING PACKAGE

30
CONFIDENTIAL & PROPRIETARY REVISION HISTORY
THIS PRINT AND THE INFORMATION CONTAINED HEREIN (PRINT) ARE THE REV DESCRIPTION DATE APPROVED
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. #15 WAS 863-1508-246, # 17 WAS 863-1008-247
THE RECIPIENT WILL MAINTAIN THE PRINT IN STRICTEST CONFIDENCE UNLESS
2X C #22 WAS 315-4112-050, ADDED #24 6/26/12
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING.
THE RECIPIENT IS GRANTED NO RIGHTS RELATING TO THE PRINT AND WITHOUT
LIMITATION SPECIFICALLY AGREES NOT TO REPRODUCE OR OTHERWISE UTILIZE
10
THE PRINT FOR THE PURPOSE OF MANUFACTURE OR SALE. 1
2
11 23 2X
4
16
Item Part Number Description Qty

14
1 315-4111-100 AVC/OSC SEGMENT ASSY 1 13
15 24 5
2 315-4122-100 DRIVE/WIRE SEGMENT ASSY 1 20
3 315-4104-115 WIRE SPOOL HOUSING ASS'Y 1
21
4 315-4105-101 TORCH ASSEMBLY 1 12
5 315-4106-155 KIT, CHAIN\LATCH, 2"TUBE 1
6 315-4008-115 CABLE ASS'Y, TOP 1
10 4423 S, SHLDR, 8-32 X 3/16 X 1, SS 2
11 315-4001-105 SENSE STRAP ASS'Y, AVC 1
12 94035A207 SHOULDER SCREW, .187 X .75 1 NOTES:
13 4425 SCREW, SHOULDER, .187X1.5, SS 1 3 1. SHIPPING CASE, TOOL KIT,
17 TORH ACCESSORY KIT, I.D. PLATE,
14 B6-11 SPACER 1 22 & LOGO LABEL ARE NOT SHOWN.
6 2. ALL FUTABA CONNECTORS MUST BE
15 863-1508-088 BHCS,#4-40X1/2,SS 1
TIED WITH WAX STRING TO PREVENT
16 315-4112-051 STRAIN RELIEF,MODIFIED 1 DISCONNECTION.
17 315-4122-052 CLEAT, LONG 1
! -
! See BOM
20 9271K38 TORSION SPRING, WIRE SPOOL 1 mjones 04/23/2012
LIBURDI DIMETRICS COPORATION
21 B6-13 SPACER 1 2599 CHARLOTTE HIGHWAY
mjones 04/23/2012
22 863-1508-092 S, BH, SD, 4-40 X 3/4, SS 1 ! MOORESVILLE, NC 28117
315-4110-101
23 863-1508-163 BHCS,#6-32X3/16,SS 2

J-HEAD TOP ASSY

24 315-4122-053 SHORT CLEAT 1

2" TUBE, DIRECT DRIVE

NONE
"
25* xxx - doc number xxx - description line1 1

1 1 315-4110-101 C
CONFIDENTIAL & PROPRIETARY
THIS PRINT AND THE INFORMATION CONTAINED HEREIN (PRINT) ARE THE
REVISION HISTORY
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. REV DESCRIPTION DATE APPROVED
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING. B ITEM 8 WAS 315-4101-022 9/13/11 MEJ
THE RECIPIENT IS GRANTED NO RIGHTS RELATING TO THE PRINT AND WITHOUT C ITEM 27 WAS 5 REQ'D, ITEM 26 WAS 2 REQ'D 9/23/11 MEJ
THE PRINT FOR THE PURPOSE OF MANUFACTURE OR SALE. D ITEM 30 WAS 2-56X1/8 863-1508-002 1/9/15 JC
E #31 WAS 6 REQ'D, #24 WAS 2 REQ'D, #30 WAS 4 REQ'D ADDED #40,41 & 42 12/30/15
ITEM PART NUMBER PART DESCRIPTION QTY 17
5 33
1 315-4001-002 AVC/OSC HOUSING COVER 1 6
11
2 315-4101-007 TORCH MOUNTING SHAFT 1 2 14 15 2X 13
3 315-4101-008 OSC INTEGRATING BRACKET 1
3X
4 315-4101-010 BRACKET, AVC MOTOR 1
4 29 39
5 315-4101-021 CAM, LIMIT SWITCH 1
34 3
6 315-4101-041 SCREW PIN, AVC DRIVEN GEAR 1
8
7 315-4101-051 DUST SHIELD, AVC/OSC HOUSING 1
8 315-4101-102 MOTOR ASSEMBLY 1 7
9 315-4101-104 OSC MOTOR SUB ASSY 1
10
10 315-4101-106 OSC SHAFT BRACKET ASSY 1 B
24
11 315-4101-110 PINION ASSEMBLY 1
12 315-4101-113 GUIDE ROLLER ASSY 4
4X 30
13 315-4101-115 AVC LIMIT SWITCH ASSY 1
14 315-4101-OP1 OSC SHAFT SLEEVE BEARING 1
26
24 27 21
15 315-4101-OP2 OSC SHAFT SLEEVE BEARING 2
16 315-4111-001 AVC/OSC HOUSING 1
22
17 315-4111-006 AVC DRIVEN GEAR 1 35
18 315-4111-011 BRACKET,MOUNTING,OSC MOTOR 1
19
20
19 315-4111-103 OSC BALL SCREW ASSY 1 27
42
20 5903-0012-3 LINEAR POT, 5K PRECISION 1 18
26
21 847-0007-004 HEX NUT, #4-40, SS 1
25
22 851-1913-031 PIN,DOWEL,3/16X5/16,SS 2 36 23
9 28 12
23 863-0205-074 SHOULDER SCREW 0.187SD X 0.252L x 8-32 SS 4 4X
2X 4X
24 863-1008-083 S, CH, SD, 4-40 X 3/16, SS 6 16
25 863-1008-087 S, CH, SD, 4-40 X 7/16, SS 1 E
26 863-1008-163 S, CH, SD, 6-32 X 3/16, SS 4

27 863-1008-165 S, CH, SD, 6-32 X 0.312, SS 3
28 863-1008-K06 SHCS, 2.5X6MM, SS 2 C
29 863-1008-L05 SHCS, M2 X 5mm, SS 3 C
30 863-1508-003 BHCS, 2-56 x 0.1875, SS 5 31

31 863-1508-082 S, BH, SD, 4-40 X 1/8SS 2 E
32 863-3008-403 SHSS, CP, 1/4-20 X 3/16", SS 1 D
33 863-3108-082 SHSS,#4-40 X 1/8, FLT PT,SS 1 38

34 863-3308-082 SHSS DG PT, 4-40 x 0.125 SS 2 31
35 ECN-06010-RZN BALL NUT, 6mm x 1mm, ALLOY STEEL 1 FINISH: NONE
36 S9912Y-G1225FS2G FLANGED BALL BEARING, 0.125 BORE 1 MATERIAL: SEE BOM
37 S9912Y-G1850FS2G FLANGED BALL BEARING, 0.187 BORE 1

30 DRAWN tjones 06/06/2011
LIBURDI 404 ARMOUR ST.
41 DIMETRICS P.O. BOX 339
ENGR
32 37 mjones 26/05/2011
CORPORATION DAVIDSON, NC 28036
40 CAD FILE:
AVC/OSC SEGMENT ASSY
315-4111-100
NOTES: UNLESS OTHERWISE SPECIFIED

40 90183A308 WASHER,#2X.312X.063,SS 1 E
1. ITEM #1, AVC/OSC HOUSING COVER REMOVED FOR CLARITY.
TOLERANCES ON
DECIMALS ANGLES
J-HEAD
41 863-1008-004 SHCS, 2-56 X 0.250, SS 1 E
2. ASSEMBLE WITH SEMI-PERMANENT THREAD LOCKER. X.X ±.030 ± 0°30 SCALE 1:1 SIZE REV
42 FPC-7M CONN, 3 PIN SLDR, MALE 1 E

X.XX ±.010 FRACTION S
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 D 315-4111-100 E
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. A Initial Release 09/13/2011
THE PRINT FOR THE PURPOSE OF MANUFACTURE OR SALE.
5
3 1.5" LG
5
2
+
RED
1
2
3 BLK
4 1.5" LG
1

!N\A
! Error: No reference
Item Part Number Description Qty mjones 09/13/2011
1 315-4101-022 MOTOR,MODIFIED 1 2599 CHARLOTTE HIGHWAY
mjones 09/13/2011
2 FPC-7M CONN, 3 PIN SLDR, MALE 1 ! MOORESVILLE, NC 28117
315-4101-102
3 884-6014-003 WIRE, 22GA, RED .20

MOTOR ASSEMBLY

4 884-6014-001 WIRE, 22GA, BLK .20

J HEAD AVC

NONE
"
5 FIT-105-1/8 HEAT SHRINK .16

1 1 315-4101-102 A
REVISION HISTORY
REV DESCRIPTION DATE APPROVED
A INITIAL RELEASE 06/02/2011
3 2
.097
.093 THRU
AT ASS'Y

!
!
mjones 06/02/2011
LIBURDI '835;89:
DIMETRICS 65(5>
mjones 06/02/2011
*'</*9544)
ITEM PART NUMBER PART DESCRIPTION QTY ! CORPORATION
315-4111-103
1 315-4111-003 BALL SCREW,MODIFIED 1

OSC BALL SCREW ASSY

2 315-4101-050 GEAR,DRIVEN 1

J-HEAD

2:1
"
3 93740A175 SPRING PIN, COILED, 3/32X3/8 1

1 1 315-4111-103 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. B ADDED WIRING AND WIRING SCHEMATIC 09/13/2011
tHE RECIPIENT WILL MAINTAIN THE PRINT IN STRICTEST CONFIDENCE UNLESS
6
5
1
Drill & Pin
@ Assembly 3
2 4
7
8
BLACK
J5 - 1
-
OSC M
+ RED
ITEM PART NUMBER PART DESCRIPTION QTY J5 - 3
1 2232T024SR+20/1 3.71:1 OSC MOTOR, J HEAD 1
2 315-4101-029 OSC DRIVE GEAR 1 FINISH: NONE
MATERIAL: See BOM
3 851-0609-011 DOWEL PIN, 0.0625" x 0.219"L SS 1
DRAWN tjones 02/03/2010
4 884-6014-001 22 AWG WIRE, BLACK 6" 2599 CHARLOTTE HIGHWAY
ENGR tjones 01/20/2010
5 884-6014-003 22 AWG WIRE, RED 6" CAD FILE: MOORESVILLE, NC 28117
OSC MOTOR SUB ASSY
315-4101-104
6 FIT-105-1/8 SLEEVE SHRINK, 1/8" ID 1/2" UNLESS OTHERWISE SPECIFIED
7 FIT-105-3/32 SLEEVE SHRINK, 3/32" ID 1/2"

TOLERANCES ON
DECIMALS ANGLES J-HEAD
X.X ±.030 ± 0°30 SCALE 1:1 SIZE REV
8 FPC-7M CONN, 3 PIN SLDR, MALE 1 X.XX ±.010 FRACTIONS

X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4101-104 B
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. A INITIAL RELEASE 02/05/2010
),1,6+ NONE
0$7(5,$/ See BOM
'5$:1
5$:1 tjones 02/05/2010
ITEM PART NUMBER PART DESCRIPTION QTY (1*
(1*5 mjones 01/26/2010
2599 CHARLOTTE HIGHWAY
&$'), /( MOORESVILLE, NC 28117
1 315-4101-020 BRACKET, TORCH SHAFT 1 315-4101-106
26&6+$)7%5$&.(7$66<
81/(6627+(5:,6(63(& ,),('
,) ,('
2 9368T49 SLEEVE BEARING 1 72/(5$1&(621
72/( 5$1&(621
'(&,0$/6 $1*/(6
$1*/(6 -+($'
;; o on n 6&$/( 6&$/ ( 1:1 6,=( 5(9
3 851-1314-050 PIN,DOWEL,1/8" X 1/2" 2 ;;; o )5$&7,21 6
;;;;
;;; ; o
o o o 6+( 6+((7 1 2) 1 % 315-4101-106 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. B ITEM #2 WAS 851-0912-500,.093/.097 WAS .093/.094 3/24/10
O .097
.093 THRU 2
.296
1
SEE NOTE 1
NOTES:
1. NOTE ORIENTATION OF COUPLER/CAM TO PINION TEETH
PRIOR TO DRILLING AND PINNING.
FINISH:
MATERIAL:
DRAWN mjones 02/02/2010
ENGR mjones 02/01/2010
ITEM PART NUMBER PART DESCRIPTION QTY CAD FILE: MOORESVILLE, NC 28117
PINION ASSEMBLY
315-4101-110
1 315-4101-005 COUPLER\CAM 1 UNLESS OTHERWISE SPECIFIED
2 93740A175 SPRING PIN, COILED,3/32X3/8LG, SS 1 B

TOLERANCES ON
3 315-4101-004 PINION, AVC, J HEAD 1 X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4101-110 B
FINISH: -
MATERIAL: See BOM
CAD FILE: MOORESVILLE, NC 28117
GUIDE ROLLER ASSY
315-4101-113
ITEM PART NUMBER PART DESCRIPTION QTY UNLESS OTHERWISE SPECIFIED
1 315-4101-012 AVC/OSC GUIDE ROLLER 1

TOLERANCES ON
2 315-4101-014 AVC/OSC GUIDE ROLLER BEARING 1 X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4101-113 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP.
tHE RECIPIENT WILL MAINTAIN THE PRINT IN STRICTEST CONFIDENCE UNLESS 3 B REMOVED 2 LOCATING PINS 05/13/2011
WIRING SCHEMATIC 8 6
1 13
CR1
IN4004
C NC
P7 - 2 P6 - 2
SW1
P7 - 1
C
SW2
NC
P6 - 1 5
CR2
10 12
IN4004
11
2
ITEM PART NUMBER PART DESCRIPTION QTY
1 315-4101-052 AVC LIMIT SWITCH HOUSING 1
2 A1SX1-T LIMIT SWITCH 2
4
3 315-4101-053 AVC LIMIT SWITH HOUSING 1
4 863-1508-005 BHCS, 2-56 x 5/16" SS 2 9
5 863-1008-005 SHCS, 2-56 X 5/16, SS 4
6 851-0609-031 PIN, DW, 1/16 X 0.3125, SS 4
7 315-4101-054 AVC LIMIT SWITCH ACTUATOR 2 FINISH: -
MATERIAL: See BOM
8 70036 COMPRESSION SPRING 2
9 1N4004 CR, RECT, 1AMP400VGP 2 2599 CHARLOTTE HIGHWAY
10 884-6014-003 WR, 22AWG STRANDED RED 1' CAD FILE: MOORESVILLE, NC 28117
AVC LIMIT SWITCH ASSY
315-4101-115
11 FPC-7M CONN, 3 PIN SLDR, MALE 1 UNLESS OTHERWISE SPECIFIED
12 884-6014-001 WR, 22AWG STRANDED BLK 1'

TOLERANCES ON
13 FPC-7M CONN, 3 PIN SLDR, FEMALE 1 X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4101-115 B
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. B ITEM 14 WAS 315-4112-049 4/25/13 mjones
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING. C ITEM 2 DRIVE MOTOR WAS 315-4122-102 2/7/14
LIMITATION SPECIFICALLY AGREES NOT TO REPRODUCE OR OTHERWISE UTILIZE 13 8 7
THE PRINT FOR THE PURPOSE OF MANUFACTURE OR SALE. 6 5
15
10
3
1 2 19 20 14 21 9 12
18

!NONE
!See BOM
mjones 04/19/2012
16 17 11 2599 CHARLOTTE HIGHWAY
mjones 04/19/2012
! MOORESVILLE, NC 28117
315-4122-100

DRIVE/WIRE SEGMENT ASSY

J-HEAD

1:1
"

1 2 315-4122-100 C
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. B ITEM 14 WAS 315-4112-049 4/25/13 mjones
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING. C ITEM 2 DRIVE MOTOR WAS 315-4122-102 2/7/14
.9*2 5&793:2'*7 )*8(7.59.43 69>

)7.;*<.7*-4:8.3,
)7.;*24947&88>
)7.;*<.7*-4:8.3,*3)(4;*7
)7.;*8-&+9+1&3,*)'*&7.3,
)7.;*7411*78-&+9
-&7)*3*))7.;*7411*7
5.3)<=88
)7.;*8-&+9,*&7
& 7.3,7*9*89>1*8-&+9
<.7*+**)&88>
)7.;*249477*9&.3*7
8(-8)=88
&5.37411=88
(&'1*(4;*7/-*&)
8-88=88
3*89.39*78*,2*3985&(*7
+-(8=1,
!NONE
!See BOM
2', '&11'*&7.3,22'47* mjones 04/19/2012
(4;*7'*&7.3, 2599 CHARLOTTE HIGHWAY
mjones 04/19/2012
8-(8=1, ! MOORESVILLE, NC 28117
315-4122-100
8-(8=88

DRIVE/WIRE SEGMENT ASSY

J-HEAD

1:1
"

2 2 315-4122-100 C
10
11 1
LE
5 ZZ
14 N O
4 E
IR
W
9 TO
BELVILLE SPRING WASHER CONFIGURATION

TYPICAL 2 PLACES
12
Item Part Number Description Qty 13 6

1 315-4113-104 WIRE DRIVE MOTOR ASS'Y 1 8
2 315-4113-031 HOUSING, WIRE FEED 1
L 3
3 A 7Y 5M PSS1006 BALL BEARING, 6MM BORE 2
OO 7 2 15
SP
4 315-4113-105 ROLLER ASS'Y, IDLER 1 E
IR
W
5 315-4103-032 BRACKET,WIRE FEED 1 OM
FR
6 863-3108-082 SHSS,#4-40 X 1/8, FLT PT,SS 2
7 U-SCLBDG 0.13-0.75 PIVOT PIN, 1/8 X 3/4 1
8 851-1314-087 DOWEL PIN, 1/8 X 7/8, SS 1
9 863-1008-L05 SHCS, M2 X 5mm, SS 3
!-
!See BOM
10 315-4103-050 CLAMP SCREW, 2 mjones 01/20/2012
11 9713K54 DISC SPRING,BELVILLE 10 mjones 01/20/2012
12 315-4103-106 FITTING ASS'Y 2
315-4113-102
13 315-4112-111 WIRE LINER 1

WIRE FEED ASS'Y

14 315-4112-110 WIRE LINER 1

J HEAD

1:1
"
15 863-3108-164 SCREW,SET,SD,FLT PT #6-32X1/4 2

1 1 315-4113-102 A

!
!
mjones 01/23/2012
mjones 01/20/2012
1 315-4113-040 BEARING,INSULATOR 1
315-4113-105
2 315-4113-010 WIRE DRIVE GEAR 1

ROLLER ASS'Y, IDLER

3 A9X17008003 SHSS,CP PT#0-80X3/32 1

J HEAD

1:1
"
4 315-4113-012 WIRE ROLLER 1

1 1 315-4113-105 A
A
DETAIL A

! -
! See BOM
tjones 05/19/2011
tjones 05/19/2011
ITEM PART NUMBER DESCRIPTION QTY ! MOORESVILLE, NC 28117
315-4112-110
1 44-564 WIRE LINER 7.5"

WIRE LINER

2 FIT-105-1/4 SLEEVE SHRINK, 1/4" ID 7.0"

J-HEAD

1:1
"
3 TFT-250/14 SV, TF, 1/16, CLR 7.5"

1 1 315-4112-110 A
A 1
DETAIL A

! -
! See BOM
tjones 05/19/2011
tjones 05/19/2011
315-4112-111
1 44-564 WIRE LINER 5.5"

WIRE LINER

2 FIT-105-1/4 SLEEVE SHRINK, 1/4" ID 5.0"

J-HEAD

1:1
"
3 TFT-250/14 SV, TF, 1/16, CLR 5.5"

1 1 315-4112-111 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. B DELETED ITEM 1 "BEARING RACE" & ITEM 4 "SLEEVE 4/30/13
THE RECIPIENT WILL MAINTAIN THE PRINT IN STRICTEST CONFIDENCE UNLESS BEARING", ADDED ITEM 15 "BEARING,BALL"
11
5 10 8 10
.096
9 7
.094 THRU 3
A
B +
RED
1
2
3
BLK
10
A .406 10
1.312 SECTION A-A 13
15 15
1.615 6 12 2
14

2 315-4113-030 BEARING ISOLATOR 1
3 315-4113-033 COUPLER, SHAFT, WIRE FEED 1
5 2342S024CR+23/1,134:1 MOTOR,WIRE FEED, J HEAD 1
6 A9X17008003 SHSS,CP PT#0-80X3/32 1
7 FPC-7M CONN, 3 PIN SLDR, MALE 1 DETAIL B
8 884-6014-001 WIRE, 22AWG, BLACK .8
9 884-6014-003 WIRE, 22AWG, RED .8
!
!
10 FIT-105-3/32 HEAT SHRINK, 3/32 .1 mjones 01/20/2012
11 S7220Y-09914 PIN,SPRING, COILED, .093 X 7/16, SS 1 2599 CHARLOTTE HIGHWAY
mjones 01/20/2012
12 315-4113-010 WIRE DRIVE GEAR 1 ! MOORESVILLE, NC 28117
315-4113-104
13 315-4113-012 WIRE ROLLER 1

WIRE DRIVE MOTOR ASS'Y

14 315-4103-035 SHAFT,WIRE FEED SUPPORT 1

J-HEAD

1:1
"
15 57155K378 BEARING,BALL,5/16X1/2X5/32 2

1 1 315-4113-104 B
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. B REDESIGN FOR LARGER WIRE LINER 05/11/2011
1
.12
#4-40 UNC
THRU TO BORE
NOTES:
1. DEVCON ITEM #1 INTO ITEM #2.
3

! -
! See BOM
mjones 05/04/2010
mjones 05/04/2010
315-4103-106
1 315-4103-037 FITTING, WIRE LINER 1

FITTING ASS'Y

2 315-4103-046 SLEEVE, WIRE LINER 1

J HEAD WIRE LINER

NONE
"
3 863-3608-082 SHSS,#4-40X1/8,NYLON TIP, SS 1

1 1 315-4103-106 B
LOCTITE IN PLACE PRIOR
2 TO INSTALLATION OF ITEM #4
3 PERMANENTLY LOCTITE IN PLACE
RED +
1
BLK-
.030 5 PERMANENTLY
RED 1 .062 (2) LOCTITE IN PLACE
.156 2 PLACES
6
BLK 2
.156 (2)
4 LOCTITE AT 45 FROM

EXISTING TAPPED HOLES
IN MOTOR FACE (2)
8 7

!-
!See BOM
MEJ 02/04/2014 LIBURDI DIMETRICS COPORATION
ITEM QTY PART # DESCRIPTION 2599 CHARLOTTE HIGHWAY
1 1 315-4122-070 DRIVE MOTOR,MODIFIED mjones 02/04/2014
2 1 315-4002-062 DRIVE MOTOR SLEEVE ! MOORESVILLE, NC 28117
3 1 315-4122-071 DRIVE GEAR 315-4122-105
4 2 851-0609-012 PIN, DW, 1/16 X 1/8, SS

DRIVE MOTOR ASSY

5
6
2
1
863-3108-084
884-6002-00
S, SET, SD, CP, 4-40 X 1/4, SS
WIRE,22AWG/2 COND

EXTENDED, J HEAD

1:1
"
7 1 FPC-7M CONN, 3 PIN SLDR, MALE
8 .16 FIT-105-1/8 HEAT SHRINK

1 1 315-4122-105 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. B #6 WAS 164-9000-2305, # 5 WAS 315-4004-018 6/27/12
A A
8
7
6
10
11
DETAIL B 5 6
7
9
2
1
ITEM PART NUMBER PART DESCRIPTION QTY B

1 315-4104-001 HOUSING,WIRE SPOOL 1 4
2 315-4004-015 AXLE,WIRE SPOOL HUB 1
3 315-4004-016 WASHER, TEFLON 1 SECTION A-A 3
4 315-4004-017 BUSHING,NYLON,MODIFIED 1
5 315-4104-018 SCREW, MODIFIED, DRAG 1 B

!
!
6 40047391 WASHER,NYLON,1/4X1/2X.032 2 B
mjones 10/07/2010
7 881-0030-025 WASHER,FLAT,1/4" 2 2599 CHARLOTTE HIGHWAY
mjones 10/06/2010
8 G-78 SPRING,COMPRESSION 1 ! MOORESVILLE, NC 28117
315-4104-115
9 164-9000-2306 NUT,BRASS 1

WIRE SPOOL HOUSING ASS'Y

10 98401A431 COTTER PIN, 1/16 X 2" 1

J HEAD

1:1
"
11 315-4004-019 PIN,WIRE SPOOL 1

1 1 315-4104-115 B
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. D DELETED ITEM 13 TORCH FITTINGS 6/25/12
17 5
27
6
ITEM PART NUMBER PART DESCRIPTION QTY 1
1 315-4105-006 TORCH HOUSING 1
2 315-4105-019 WIRE SUPPORT POST 1 3
3 315-4105-023 VERTICAL ADJUSTMENT SCREW 1
4 315-4105-115 TORCH BODY ASSEMBLY 1
16 4
5 315-4105-116 BACK CAP ASSEMBLY 1
11
26
6 315-4105-017 WIRE NOZZLE PIVOT ARM 1 29
7 315-4105-008 WIRE NOZZLE ARM 1
7 2
8 315-4105-018 PIVOT BLOCK 1 20 25
10 23 14 15
19 24 8
9 98408A126 E RING, 3/16 1
18 28
10 315-4105-022 HORIZONTAL ADJUSTMENT SCREW 1 12
11 98408A116 RING,RETAINING,"E" STYLE,1/8 2
12 315-4105-105 TORCH SUPPORT ARM ASSY 1
14 315-4005-044-2 COLLET,ELECTRODE,3/32 1
15 315-4005-046 TUNGSTEN ELECTRODE, 3/32 1 9
16 851-0609-050 PIN, DW, 1/16 X 1/2, SS 2
17 315-4105-005 COVER, TORCH FITTINGS 1
18 315-4105-068 CLEAR SHIELD CUP 1
19 863-1008-166 S, CH, SD, 6-32 X 3/8, SS 1
20 92845A140 SHSS, #6-32 X 3/16 SS 1
21 22
21 863-0205-073 Shoulder, SH, 8-32, 1/2 X 3/16, SS 1
22 863-1008-172 S, CH, SD, 6-32 X 3/4, SS 1

! -
23 315-4105-007 WIRE NOZZLE, .035 WR 1 ! See BOM
tjones 01/18/2010
24 315-4105-084 FITTING, WIRE LINER 1 LIBURDI '835;89:
DIMETRICS 65(5>
25 9464K21 O RING,VITON,9/16X11/16 1 tjones 01/08/2010
*'</*9544)
! CORPORATION
26 863-3008-162 SHSS, KNCP, 6-32 X 0.125, SS 1 315-4105-101
27 863-1508-003 BHCS, 2-56 x 0.1875, SS 4

TORCH ASSEMBLY

28 315-4105-118 GAS LENS ASSY 1

J-HEAD

1:1
"
29 863-1008-084 S, CH, SD, 4-40 X 0.250, SS 1

1 1 315-4105-101 D
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. C ITEM 3 WAS 2 REQ'D, ADDED ITEM 5 10/25/11
2
3
1

! NONE
! See BOM
ITEM PART NUMBER DESCRIPTION QTY
tjones 01/18/2010
LIBURDI '835;89:
1 315-4105-002 TORCH CLAMP 1 DIMETRICS 65(5>
tjones 01/08/2010
*'</*9544)
2 315-4105-1G2 TORCH SUPPORT ARM 1 ! CORPORATION
315-4105-105
3 863-1008-166 S, CH, SD, 6-32 X 3/8, SS 1

TORCH SUPPORT ARM ASSY

4 851-1314-035 PIN, DW, 1/8 X 0.360, SS 1

J-HEAD

1:1
"
5 863-1008-366 SHCS,#10-32 X 3/8LG, SS 1

1 1 315-4105-105 C
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. A Initial Release 01/15/2010 mjones
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING. B ITEM #3 WAS 863-1097-013 1/25/10 MEJ
THE RECIPIENT IS GRANTED NO RIGHTS RELATING TO THE PRINT AND WITHOUT C ITEM #2 WAS 315-4105-053 4/6/10 MEJ
THE PRINT FOR THE PURPOSE OF MANUFACTURE OR SALE. D ADDED ITEM #4, REORDERED NOTES 6/25/12 MEJ
E NOTE 3 WAS "FURNACE BRAZE ONLY" 10/11/15
1
3
D NOTES:
4 1. IDENTIFY WITH PART NUMBER & REVISION.
2. REMOVE ALL BURRS AND SHARP EDGES
3. PRESS ITEM #2 INTO ITEM #1. BRAZE INDICATED JOINTS. USE HIGH
2 MELTING POINT SOLDER TO SEAL THE JOINT, BOTH SIDES.
4. THREAD ITEM #3 INTO ITEM #1. MUST BE FLUSH OR
BELOW. INSTALL ITEMS #4. SEAL USING DEVCON "F"
OR EQUIVALENT
FINISH:
MATERIAL:
Item Part Number Description Qty DIMETRICS P.O. BOX 339
DAVIDSON, NC 28036
1 315-4105-052 TORCH BODY 1 CAD FILE: CORPORATION
TORCH BODY ASSEMBLY
315-4105-115
2 315-4105-054 TORCH BODY INSERT 1 UNLESS OTHERWISE SPECIFIED
3 863-3008-362 S, SET, SD, CP, 10-32 X 1/8, SS 1

TOLERANCES ON
4 310-3106-008 TORCH CONNECT FITTING 3 D X.XX ±.010 FRACTIONS

X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4105-115 E
LOCATE 90°FROM FLATS

4 ON ITEM #1 AT ASSEMBLY
DRILL THRU ITEMS #1 & #2
1

!
!
mjones 01/11/2010
LIBURDI '835;89:
Item Part Number Description Qty DIMETRICS 65(5>
mjones 01/08/2010
*'</*9544)
1 315-4105-032 BODY, NEW,BACK CAP 1 ! CORPORATION
315-4105-116
2 315-4105-031 KNOB,STAR, 1

BACK CAP ASSEMBLY

3 9464K14 O-RING,SIZE -009,VITON 1

J-HEAD

NONE
"
4 851-0611-056 PIN,ROLL,1/16X9/16,SS 1

1 1 315-4105-116 A
2 4

! -
! See BOM
tjones 05/10/2010
ITEM PART NUMBER PART DESCRIPTION QTY 2599 CHARLOTTE HIGHWAY
tjones 05/10/2010
1 315-4105-090 GAS LENS THREADED INSERT 1 ! MOORESVILLE, NC 28117
315-4105-118
2 315-4005-067 INTERMEDIATE SCREEN 4

GAS LENS ASSY

3 315-4005-065 INNER SCREEN 3

J-HEAD

1:1
"
4 860-0010-188 E-STYLE RETAINING RING 1

1 1 315-4105-118 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP.
B Revised Print 01/25/2012
5

!-
!See BOM
tjones 01/25/2012
mjones 06/20/2011
315-4106-155

KIT, CHAIN\LATCH, 2"TUBE

DIRECT DRIVE

1:1
"

1 1 315-4106-155 B
Kit,Chain\Latch,J Head,2"Dia, Direct Drive
P\N 315-4106-155

0001 315-4106-106 1 LATCH\CHAIN ASSY,J-HEAD,2" TUBE,1.5" PIPE
0002 315-4106-1G10 1 SPACER, INTERSEGMENT, J HEAD, 2" DIRECT DRIVE
0003 863-1508-246 1 A014036 S, BH, SD 8-32 X 3/8 SS
0004 315-4001-032 1 LATCH BRACKET,SHORT
0005 863-1508-243 2 A014043 S,BH,SD,8-32X3/16,SS
LIMITATION SPECIFICALLY AGREES NOT TO REPRODUCE OR OTHERWISE UTILIZE 10
6
3
2
7
1

5
1 315-4006-003 SCREW, SHOULDER, MODIFIED 1
2 315-4106-004 BRACKET,WIRE GUIDE 1 11
3 315-4006-021 LATCH HANDLE 1
4 315-4006-024 SHORT LATCH BRIDGE 1
5 315-4006-027 LINK,LATCH,1-1/8 1 FINISH: -
MATERIAL: See BOM
6 315-4006-120 ROLLER ASSEMBLY 2
7 315-4106-102 LATCH BRACKET ASSEMBLY 1 2599 CHARLOTTE HIGHWAY
8 4418 SHSS,3/16X5/16,#8-32 3 CAD FILE: MOORESVILLE, NC 28117
LATCH/CHAIN ASSY
315-4106-106
9 851-1314-125 PIN, DOWEL, 1/8 X 1-1/4, SS 1 UNLESS OTHERWISE SPECIFIED
10 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1

TOLERANCES ON
DECIMALS ANGLES 1-1/2" PIPE, 1.90 OD
11 863-1508-165 S, BH, SD, 6-32 X 0.312, SS 1 X.XX ±.010 FRACTIONS

X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-106 A
5 2
FINISH:-
Item Document Number Description Qty MATERIAL:See BOM
1 315-4106-120ST LATCH/CHAIN ASSY,SPECIAL 1
LIBURDI DIMETRICS CORPORATION
2 315-4106-1G23 SPACER, INTER SEGMENT 1 CAD FILE: MOORESVILLE, NC 28117
KIT,CHAIN\LATCH,SPECIAL
315-4106-173ST
3 863-1508-246 BHCS, 8-32 X 0.3/8", SS 1 UNLESS OTHERWISE SPECIFIED
4 315-4001-031 LATCH BRACKET LARGE O.D. 1

TOLERANCES ON
DECIMALS ANGLES 3-1/2" PIPE TRACK
5 863-1508-243 BHSD 8-32 X 3/16 (0.1875), SS 2 X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-173ST A
2
8 5
3
12
4
1
7
Item Document Number Description Qty 6
1 315-4006-024 SHORT LATCH BRIDGE 1 9
11
2 315-4006-021 LATCH HANDLE 1 10
3 315-4106-102 LATCH BRACKET ASSEMBLY 1
6 4418 SHSS,3/16X5/16,#8-32 7
FINISH:-
7 851-1314-125 PIN, DOWEL, 1/8 X 1-1/4, SS 1 MATERIAL:See BOM
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1
9 315-4006-027 LINK,LATCH,1-1/8 2 CAD FILE: MOORESVILLE, NC 28117
LATCH/CHAIN ASSY,SPECIAL
315-4106-120ST
10 315-4006-029 LINK,LATCH,1-5/8 3 UNLESS OTHERWISE SPECIFIED
11 863-1508-165 S, BH, SD, 6-32 X 0.312, SS 1

TOLERANCES ON
DECIMALS ANGLES J HEAD 3-1/2" PIPE TRACK
12 315-4106-004 BRACKET,WIRE GUIDE 1 X.XX ±.010 FRACTIONS
3
4
5
FINISH:-
1 315-4106-120 LATCH/CHAIN ASSY 1
2 315-4106-1G33 SPACER,INTERSEGMENT, 1 CAD FILE: MOORESVILLE, NC 28117
KIT, CHAIN\LATCH
315-4106-173

TOLERANCES ON
DECIMALS ANGLES 3-1/2 PIPE, 4.00 OD
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-173 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. A Initial Release 06/05/2014 JC
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING. B ITEM 1 WAS 315-4106-108 11/04/15
3
4
8
9
Item Document Number Description Qty

7
10
3 315-4006-021 LATCH HANDLE 1
4 315-4006-120 ROLLER ASSEMBLY 5 11
5 4418 SHSS,3/16X5/16,#8-32 6 12
13
6 315-4006-003 SCREW, SHOULDER, MODIFIED 4 12 5
7 851-1314-125 PIN, DOWEL, 1/8 X 1-1/4, SS 1
FINISH:-
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1 MATERIAL:See BOM
9 315-4106-004 BRACKET,WIRE GUIDE 1
10 315-4006-027 LINK,LATCH,1-1/8 1 CAD FILE: MOORESVILLE, NC 28117
LATCH/CHAIN ASSY
315-4106-120
11 863-1508-165 S, BH, SD, 6-32 X 0.312, SS 1 UNLESS OTHERWISE SPECIFIED
12 315-4006-029 LINK,LATCH,1-5/8 2
TOLERANCES ON
13 315-4006-028 LINK,LATCH,1-3/8 1 X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-120 B
FINISH:-
1 315-4106-119ST LATCH/CHAIN ASSY, SPECIAL 1 5 LIBURDI DIMETRICS CORPORATION
KIT, CHAIN\LATCH,SPECIAL
315-4106-172ST
4 863-1508-245 S, BH, SD, 8-32 X 0.313, SS 2

TOLERANCES ON
DECIMALS ANGLES 3" PIPE TRACK
5 315-4001-031 LATCH BRACKET LARGE O.D. 1 X.XX ±.010 FRACTIONS
3
4
9
1
2
6

7
2 315-4006-024 SHORT LATCH BRIDGE 1 11
3 315-4006-021 LATCH HANDLE 1 10
12 5
5 4418 SHSS,3/16X5/16,#8-32 6
FINISH:-
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1
9 315-4106-004 BRACKET,WIRE GUIDE 1 CAD FILE: MOORESVILLE, NC 28117
LATCH/CHAIN ASSY, SPECIAL
315-4106-119ST
11 315-4006-029 LINK,LATCH,1-5/8 2
TOLERANCES ON
3
4
5
FINISH:-
KIT, CHAIN\LATCH
315-4106-172

TOLERANCES ON
DECIMALS ANGLES 3" PIPE, 3.50 OD
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-172 A
3
4
8
9
1
6 2

7
10
3 315-4006-021 LATCH HANDLE 1

11
12
12
5 4418 SHSS,3/16X5/16,#8-32 5 5
FINISH:-
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1
LATCH/CHAIN ASSY
315-4106-119
10 315-4006-027 LINK,LATCH,1-1/8 1 UNLESS OTHERWISE SPECIFIED
11 863-1508-165 S, BH, SD, 6-32 X 0.312, SS 1

TOLERANCES ON
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-119 A
FINISH:-
1 315-4106-118ST LATCH/CHAIN ASSY, SPECIAL 1 5 LIBURDI DIMETRICS CORPORATION
KIT, CHAIN\LATCH,SPECIAL
315-4106-171ST
4 863-1508-245 S, BH, SD, 8-32 X 0.313, SS 2

TOLERANCES ON
DECIMALS ANGLES 2-1/2 PIPE TRACK
5 315-4001-031 LATCH BRACKET LARGE O.D. 1 X.XX ±.010 FRACTIONS
4
8
1 9
6
2

7
11
3 315-4006-021 LATCH HANDLE 1 10
12
5 4418 SHSS,3/16X5/16,#8-32 5
FINISH:-
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1
315-4106-118ST
11 315-4006-029 LINK,LATCH,1-5/8 1
TOLERANCES ON
DECIMALS ANGLES 2-1/2" PIPE TRACK
3
4
5
FINISH:-
KIT, CHAIN\LATCH
315-4106-171

TOLERANCES ON
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-171 A
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. A Initial Release 06/05/2014 MEJ
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING. B ITEM 1 WAS 315-4106-108 11/04/15
3
9
1
2
6

7
10
12
3 315-4006-021 LATCH HANDLE 1
13 11
4 315-4006-120 ROLLER ASSEMBLY 4 12 5
5 4418 SHSS,3/16X5/16,#8-32 5
FINISH:-
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1
LATCH/CHAIN ASSY
315-4106-118
12 315-4006-029 LINK,LATCH,1-5/8 2
TOLERANCES ON
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-118 B
3
4
FINISH:-
1 315-4106-117ST LATCH/CHAIN ASSY, SPECIAL 1
KIT, CHAIN\LATCH
315-4106-170ST

TOLERANCES ON
8 4
1
9
6
2

7
11
3 315-4006-021 LATCH HANDLE 1 10
12
5 4418 SHSS,3/16X5/16,#8-32 4
FINISH:-
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1
315-4106-117ST
11 315-4006-029 LINK,LATCH,1-5/8 1
TOLERANCES ON
THE PRINT FOR THE PURPOSE OF MANUFACTURE OR SALE. 3
5
4
FINISH:-
ENGR mjones 1/30/15
KIT, CHAIN\LATCH
315-4106-169
4 315-4001-032 LATCH BRACKET, SHORT 1

TOLERANCES ON
5 863-1508-243 S, BH, SD, 8-32 X 3/16, SS 2 X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-170 A
5
2
9
3
4

10
2 315-4006-021 LATCH HANDLE 1 11
5 315-4006-120 ROLLER ASSEMBLY 2 FINISH: -
MATERIAL: See BOM
6 4418 SHSS,3/16X5/16,#8-32 3
7 851-1314-125 PIN, DOWEL, 1/8 X 1-1/4, SS 1 2599 CHARLOTTE HIGHWAY
ENGR
8 851-1913-125 PIN, DW, 3/16 X 1-1/4, SS 1 CAD FILE: MOORESVILLE, NC 28117
LATCH/CHAIN ASSY
315-4106-106
9 315-4106-004 BRACKET,WIRE GUIDE 1 UNLESS OTHERWISE SPECIFIED
10 315-4006-035 LINK,LATCH,1-5/8 RELIEVED 1

TOLERANCES ON

X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4106-117 A
REVISION HISTORY
B ITEM #3 WAS #5-40X3/4,SS 2/16/09 mjones
C ITEM #4 WAS 851-1314-112 12/7/09
1 2
FINISH:
MATERIAL:
Item Part Number Title Qty DIMETRICS P.O. BOX 339
DAVIDSON, NC 28036
1 315-4006-030 LATCH BRACKET HINGE 1 CAD FILE: CORPORATION
LATCH BRACKET ASS'Y
315-4006-102
2 315-4006-031 LATCH BRACKET,CLAMP 1 UNLESS OTHERWISE SPECIFIED
3 863-1003-172 SHCS, #6-32X3/4, ALLOY STEEL 1

TOLERANCES ON
DECIMALS ANGLES J HEAD
4 90145A882 PIN, DOWEL, 1/8 X 1-1/8, SS 2 X.XX ±.010 FRACTIONS

X.XXX ±.005 ± 1/32 SHEET 1 OF 1 B 315-4006-102 C
REVISION HISTORY
A Initial Release 10/04/2009
2 1

! -
! See BOM
MEJ 10/04/2009 LIBURDI '835;89:
DIMETRICS 65(5>
mjones 10/04/2009
*'</*9544)
! CORPORATION
315-4006-120
Item Part Number Title Qty

ROLLER ASSEMBLY

1 315-4006-002 LATCH ROLLER 1

J-HEAD CHAIN/LATCH

4:1
"
2 A 7B 4-P144 SLEEVE BEARING,BRONZE 1

1 1 315-4006-120 B
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. D MULTIPLE BOM REVISIONS ECR 030915-1 09/03/2015
TO P300 2 8 1 24'5"
ELECTRODE
7 4 5 6 24' B
WATER
26 '
B
8 2X 38 2X
3 4 5 6 24' 37 5X 17 19 20
C 16
36
14 2X
8
WATER
4
A
35 B&C
38 8 9 24'6"
D
GAS OUT E J2
D
2X
5 23 21 2X 22 18
24 '6"
10 11 12 13 25 24 33 GAS LINE 27 26
8 15 25'
WELDHEAD
P1 E
22 32 2X
28 29 30 31 39
FINISH:
PCB A1 MATERIAL:
CALIBRATION DRAWN TMJ 11/6/09
BOARD LIBURDI DIMETRICS CORPORATION
18 " ENGR
CABLE ASS'Y,25FT
315-4008-105
UNLESS OTHERWISE SPECIFIED
TOLERANCES ON
DECIMALS ANGLES J HEAD TO P300
X.X ±.030 ± 0°30 SCALE NONE SIZE REV
X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 2 B 315-4008-105 D
CONFIDENTIAL AND PROPRIETARY PROPERTY OF LIBURDI DIMETRICS CORP. A INITIAL RELEASE 03/17/2010 AWB
OTHERWISE SPECIFICALLY AUTHORIZED BY LIBURDIDIMETRICS CORP IN WRITING. B REPLACED ITEM 4 WITH ITEM 26 05/14/2010 TMJ
THE RECIPIENT IS GRANTED NO RIGHTS RELATING TO THE PRINT AND WITHOUT C ADDED ITEM #28 08/27/2010 TMJ
THE PRINT FOR THE PURPOSE OF MANUFACTURE OR SALE. D CORRECTED J8 WIRING 09/14/2011 AWB
E UPDATED PRINT 09/16/2011 AWB
1. IDENTIFY WITH PART # 310-3106-106 RV F. F REMOVED IDENTIFICATION JUMPER 09/17/2011 AWB
2. SLIDE 88P TUBING OVER FITTING AND SECURE WITH SELF G MULTIPLE BOM CHANGES, ECR# 110915-1 09/24/2015
POTTING HEAT SHRINK. THIS ACTS AS A STRAIN RELIEF FOR
THE TIG FITTING.
3. SOLDER TIG LINE AFTER CRIMPING TO TIG LINE FITTING 15 Ft
USING LEAD FREE TINNING FLUX & 60/40 ROSIN CORE 3 15"
SOLDER.
1 20 21 26 27 Make all the same length
4.APPLY LOCTITE 680 TO ITEM 20 WHEN THREADED INTO
ITEM 1 2
6 19 11 25 34 3 28 15
LENGTH OF INDIVIDUAL LINES TO HEAD 23 4.0" 22 3.0"
TO
TORCH
TIG/WATER RETURN 180" (15')
WATER SUPPLY 180" (15') TIG LINE E TIG LINE TIG LINE E
GAS 179" (14'-11") 15 28

TIG LINE E
CONTROL CABLE 176" (14'-8") TIG LINE E TIG LINE
TORCH GAS TORCH GAS G 28 29

CONTROL
P2 AVNSNS
17"
LENGTH OF CONTROL LINES FROM STRIPPED END 8" 14'8" 4"
LINES TO J3 4" J3 TRAVEL MOTOR 35
30 2 16
LINES TO J4 4" 26
LINES TO J5 33
8" 26 6 8 9 30 31 3 10 4"
LINES TO J6 8" J4 WIRE MOTOR
LINES TO J7 17
8"
AVPSNS 14"
AVNSNS 17" 14"
AVPSNS
THETA J8 17" 2
8" J5 OSC MOTOR
8" J6 OSC POT
FROM TO COLOR DESCRIPTION 8" J7 AVC
P2-C J3-2 BLK FXDRIV

P2-D J3-1 WHT FXRRTN
P2-G J4-1 RED WFDRIV 32 18 5X
P2-E J4-3 GRN WFRRTN
P2-H J5-1 ORG OSCDRIV
P2-J J5-3 BLU OSCRTN 17" J8 THETA
P2-V J6-1 WHT/BLK P10REF
(**ADDED ONLY FOR TILT FRONT END**)
P2-R J6-3 RED/BLK N10REF
P2-S J6-2 GRN/BLK OSC FEEDBACK
FINISH:
P2-L J7-2 ORG/BLK AVDRIV
P2-M J7-1 BLU/BLK AVRRTN MATERIAL:
DRAWN jcromer 09/24/2015
P2-U LUG RED/WHT AVNSNS (ARC VOLTAGE NEGATIVE SENSE)
P2-P LUG BLK/WHT AVPSNS (ARC VOLTAGE POSITIVE SENSE)
ENGR AWB 3/17/2010
P2-Y J8-1 GRN/WHT THETADRV
CABLE ASSY, 15 FT
315-4008-106
P2-Z J8-2 BLU/WHT THETARTN
UNLESS OTHERWISE SPECIFIED
TOLERANCES ON
B 315-4008-106
P2-X FLOAT SHIELD SHIELD X.XX ±.010 FRACTIONS
X.XXX ±.005 ± 1/32 SHEET 1 OF 1 G

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J-HEAD

OPERATIONS AND MAINTENANCE MANUAL

Liburdi Dimetrics does not warrant or assume responsibility for damage to

Without specific written authorization, Liburdi Dimetrics does not warrant or

ALL RIGHTS RESERVED UNDER THE COPYRIGHT LAWS

OPERATIONS AND MAINTENANCE MANUAL 315-4110-901

Anyone who is working in industry should know the importance of safety,

Voltages and current inside of the welding equipment may be lethal;

ATTITUDE & GENERAL RULES OF SAFETY

Storage areas must be kept clean and secure.

It is your responsibility to caution anyone you think is violating safety rules.

Work at a pace consistent with safety. Rushing to complete a procedure is

If a piece of equipment or tool is not working properly, either have it

OPERATIONS AND MAINTENANCE MANUAL 315-4110-901

Consider every electrical circuit to be "LIVE" unless it is proven otherwise.

Do not work alone.

When compressed air is used for cleaning, wear eye protection.

OPERATIONS AND MAINTENANCE MANUAL 315-4110-901

Wear protective clothing when working around chemicals, radioactive

Always wash your hands after working with grease or chemicals.

Never leave tools where they may cause injury.

Keep tools from projecting over edges of benches or equipment.

These are just common sense rules: and by using

OPERATIONS AND MAINTENANCE MANUAL 315-4110-901

PROTECT YOURSELF AND OTHER FROM POSSIBLE SERIOUS INJURY OR

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR

ELECTRIC SHOCK CAN KILL

ARC RAYS CAN BURN EVES AND SKIN;

Operations Electrode Size Filter Operations Electrode Size Filter

FUMES AND GASES CAN BE

WELDING CAN CAUSE FIRE OR

FLYING SPARKS AND HOT METAL CAN

CYLINDERS CAN EXPLODE IF DAMAGED.

CONSIDERATIONS ABOUT WELDING AND THE EFFECTS

The following is a quotation from the General Conclusions Section of the

“…there is now a very large volume of scientific findings based on

To reduce magnetic fields in the workplace, use the following procedures:

PRINCIPAL SAFETY STANDARDS

ECR/ECN DATE REV DESCRIPTION REVISED BY APPROVED BY

1001-01 6/24/11 A Initial Release AWB AWB

SECTION 1 - SYSTEM OVERVIEW ..................................................... 2

Operations and Maintenance Manual 315-4110-901

1. A GT VI/P300/P300 Power Supply

3. A Weld Head (like a J Head) and appropriate Tracks

4. Any Optional Extension Cable Sets

5. Any Optional Remote Viewing or Data Acquisition Subsystem

Fuse & Jumper Settings

Axis External FuseValue DSB Jumper Setting LDC Part Number

Travel 0.5A Fast Blow 1.0A AGC1/2

Oscillation 0.75A Slow Blow 2.0A 827-0001-007

AVC 0.5A Slow Blow 1.0A MDL-0.5

Wire Feed 1.5A Slow Blow 2.0A MDL-1.5A

Operations and Maintenance Manual 315-4110-901

The Front End Assembly contains the following elements:

¾ A Wire Manipulator with manual up/down and in/out wire adjustment

Operations and Maintenance Manual 315-4110-901

¾ DC Drive 75 IPM Main Wire Feed Motor

J-HEAD FUNCTIONS AND PARAMETERS

Test Date(s): __ Technician(s):_