Lincoln Electric LN-22 Contactor - 8803 Instrukcja obsługi

 C WELDERS
IM-282
IM282
LN-22
March, 1987
7552; 7625; 7708;
7722; 7749; 7809;
8565; 8624; 8732;
8803; 8946
LN-22
PORTABLE INNERSHIELD® SEMIAUTOMATIC
WIRE FEEDER
DAMAGE CLAIMS
When this equipment is shipped, title passes to the
purchaser upon receipt by the carrier. Consequently,
claims for material damaged in shipment must be
made by the purchaser against the transportation
company at the time the equipment is received.
This manual covers
equipment which
is obsolete and no
longer in production
by The Lincoln Electric
Co. Specifications
and availability of
optional features
may have changed.
For an operating manual for
discontinued models
below code 7550, see IM-258-C.
SAFETY DEPENDS ON YOU
Lincoln welders are designed and built with safety in
mind. However, your overall safety can be increased by
proper installation . . . and thoughtful operation on
your part. DO NOT INSTALL, OPERATE OR RE-
PAIR THIS EQUIPMENT WITHOUT READING
THIS OPERATING MANUAL AND THE ARC
WELDING SAFETY PRECAUTIONS ON THE IN-
SIDE FRONT COVER. And, most importantly, think
before you act and be careful.
World's Largest Manufacturer of Arc Welding Products + Manufacturer of Industrial Motors
E THE LINCOLN ELECTRIC COMPANY
ELECTRIC
Sales and Service Worldwide
Cleveland, Ohio 44117-1199 U.S.A.
|. HAVE ALL
Arc Welding Safety Precautions
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ
AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING
MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS
THE FOLLOWING GENERAL INFORMATION.
INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR WORK performed
only by qualified people.
>
ELECTRIC SHOCK can kill.
Protect yourself from possible dangerous electrical
shock:
a.
J.
The electrode and work (or ground) circuits are elec-
trically “hot” when the welder is on. Never permit
contact between “hot” parts of the circuits and bare
skin or wet clothing. Wear dry, hole-free gloves to
insulate hands.
. Always insulate yourself from the work and ground
by using dry insulation. When welding in damp lo-
cations, on metal floors, gratings or scaffolds, and
when in positions such as sitting or lying, make cer-
tain the insulation is large enough to cover your full
area of physical contact with work and ground.
. Always be sure the work cable makes a good electri-
cal connection with the metal being welded. The
connection should be as close as possible to the area
being welded.
. Ground the work or metal to be welded to a good
electrical ground.
. Maintain the electrode holder, work clamp, welding
cable and welding machine in good, safe operating
condition,
Never dip the electrode in water for cooling.
. Never simultaneously touch electrically “hot” parts
of electrode holders connected to two welders be-
cause voltage between the two can be the total of
the open circuit voltage of both welders.
. If using the welder as a power source for mechanized
welding, the above precautions also apply for the
automatic electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun.
. When working above floor level, protect yourself
from a fall should you get a shock.
Also see Items 6¢ and 8.
3. FUMES AND GASES can be dangerous to your health.
a.
Welding may produce fumes and gases hazardous
to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to
keep fumes and gases away from the breathing zone.
When welding on galvanized, lead or cadmium
December 1985
e.
plated steel and other metals which produce toxic
fumes, even greater care must be taken.
Do not weld in locations near chlorinated hydrocar-
bon vapors coming from degreasing, cleaning or
spraying operations. The heat and rays of the arc
can react with solvent vapors to form phosgene, a
highly toxic gas, and other irritating products.
. Shielding gases used for arc welding can displace
air and cause injury or death. Always use enough
ventilation, especially in confined areas, to insure
breathing air is safe.
Read and understand the manufacturer’s instructions
for this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and
follow your employer’s safety practices.
Also see item 9b.
4. ARC RAYS can injure eyes and burn skin.
a.
Use a shield with the proper filter and cover plates
to protect your eyes from sparks and the rays of
the arc when welding or observing open arc welding.
Headshield and filter lens should conform to ANSI
787.1 standards.
Use suitable clothing made from durable, flame-
resistant material to protect your skin and that of
your helpers from the arc rays.
. Protect other nearby personnel with suitable non-
flammable screening and/or warn them not to watch
the arc nor expose themselves to the arc rays or
to hot spatter or metal.
5. FIRE OR EXPLOSION can cause death or property
damage.
a.
Remove fire hazards well away from the area. If
this is not possible cover them to prevent the welding
sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily
go through small cracks and openings to adjacent
areas. Have a fire extinguisher readily available.
. Where compressed gases are to be used at the job
site, special precautions should be used to prevent
hazardous situations. Refer to “Safety in Welding
and Cutting” (ANSI Standard Z49.1) and the operat-
ing information for the equipment being used.
. When not welding, make certain no part of the elec-
trode circuit is touching the work or ground. Acci-
dental contact can cause overheating and create a
fire hazard.
d.
©.
f.
Do not heat, cut or weld tanks, drums or containers
until the proper steps have been taken to insure that
such procedures will not cause flammable or toxic
vapors from substances inside. They can cause an
explosion even though they have been “cleaned.”
For information purchase “Recommended Safe Prac-
tices for the Preparation for Welding and Cutting
of Containers and Piping That Have Held Hazardous
Substances.”, AWS F4.1-80 from the American
Welding Society (see address below).
Vent hollow castings or containers before heating,
cutting or welding. They may explode.
Also see items 6c and 9c.
6. For Welding in General.
a.
Droplets of molten slag and metal are thrown or
fall from the welding arc. Protect yourself with oil
free protective garments such as leather gloves,
heavy shirt, cuffless trousers, high shoes and a cap
over your hair. Wear ear plugs when welding out
of position or in confined places. Always wear safety
glasses when in a welding area. Use glasses with
side shields when near slag chipping operations.
. Keep all equipment safety guards, covers and de-
vices in position and in good repair. Keep hands,
hair, clothing and tools away from V-belts, gears,
fans and all other moving parts when starting,
operating or repairing equipment.
. Be sure the work cable is connected to the work
as close to the welding area as practical. Work cables
connected to the building framework or other loca-
tions some distance from the welding area increase
the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains
or cables until they fail.
7. For Gas-Shielded Arc Welding.
a.
Use only compressed gas cylinders containing the
correct shielding gas for the process used and prop-
erly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suit-
able for the application and maintained in good con-
dition.
. Always keeps cylinders in an upright position sec-
urely chained to an undercarriage or fixed support.
Cylinders should be located:
® Away from areas where they may be struck or
subjected to physical damage.
e A safe distance from arc welding or cutting oper-
ations and any other source of heat, sparks, or flame.
Never allow the electrode, electrode holder, or any
other electrically “hot” parts to touch a cylinder.
. Keep your head and face away from the cylinder
valve outlet when opening the cylinder valve.
December 1985
f.
Valve protection caps should always be in place and
handtight except when the cylinder is in use or con-
nected for use.
Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publica-
tion P-1 “Precautions for Safe Handling of Compres-
sed Gases in Cylinders” available from the Compres-
sed Gas Association, 1235 Jefferson Davis High-
way, Arlington, VA 22202.
8. For Electrically Powered Equipment.
a.
Turn off input power using the disconnect switch
at the fuse box before working on the equipment.
~ Make the electrical installation in accordance with
the National Electrical Code, all local codes and the
manufacturer” s recommendations.
. Properly ground the equipment in accordance with
the National Electrical Code and the manufacturer’s
recommendations.
9. For Engine Powered Equipment.
a.
Turn the engine off before troubleshooting and
maintenance work unless the maintenance work re-
quires it to be running.
. Operate the internal combustion engines in open,
well-ventilated areas or vent the engine exhaust
fumes outdoors.
. Do not add the fuel near an open flame, welding
arc or when the engine is running. Stop the engine
and, if possible, allow it to cool when refueling to
prevent spilled fuel from vaporizing on contact with
hot engine parts and igniting. Do not spill fuel when
filling tank. If fuel is spilled, wipe it up and do
not start engine until fumes have been eliminated.
. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when
the maintenance requiring their removal is complete.
Always use the greatest care when working near
moving parts.
. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing
on the throttle control rods while the engine is run-
ning.
To prevent accidentally starting gasoline engines
while turning the engine or welding generator during
maintenance work, disconnect the spark plug wires,
distributor cap or magneto wire as appropriate.
. To avoid scalding, do not remove the radiator pres-
sure cap when the engine 1s hot.
For more detailed information it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting
— ANSI Standard Z49.1” from the American Welding So-
ciety, P.O. Box 351040 Miami, Florida 33135.
RATING
The LN-22 is designed for welding with 13'/2 and 14-
pound coils of .068” through %/64” Innershield self-
shielded electrodes. A constant voltage DC power
source is recommended or use with the LN-22. How-
ever, LN-22’s above code 7800 can operate with DC
power sources where the OCV can be limited to 70
volts maximum with a low ripple content.
ELECTRODE AND WORK CABLE
Copper Cable Size for
Combined Lengths of Electrode
and Work Cables
Amps | Duty Cycie| 0 — 100’ | 100’ - 150 | 150° — 200’
300 60% 1 1 1/0
350 60% 1/0 2/0 2/0
If larger than 1/0 cables are used, a size 1/0 whip lead is required
to connect the input cable to the QD connector.
Turn off the power source and connect one end of the
needed length of work cable to the power source work
stud and the other end to the work.
Remove the female QD connector from the back of
the wire feeder. Solder the QD connector to a cable
of sufficient length to reach the electrode stud on the
power source per instructions shipped with the
LN-22. With the wire drive housing door closed, in-
sert the QD connector into the fitting in the back of
the wire feeder and connect the other end to the ap-
propriate stud on the power source. (If installed in
this manner the connector acts as an interlock for the
wire drive housing door.)
DRIVE ROLL PRESSURE
Do not adjust the drive roll pressure. If the idle roll
tension must be relieved temporarily, see REPLAC-
ING DRIVE ROLLS in the maintenance section of
this manual.
POWER SOURCE CONNECTION AND
CONTROL SETTING
For highest quality Innershield welds use a Constant
Voltage DC Power Source. The DC-400, SAM or R3S
(with Voltage Compensator option where input line
voltage variation exceeds + 3%) or appropriate Lincoln
welders with C.V. adapters are recommended.
A. Idealarc® R3S-325, R3S-400, -600 and -800 Weld-
ers. (Turn off the power source.)
1. Use of the optional Line
Voltage Compensator
available with R3S-325,
-400 and -600 welders 1s
B.
. Turn off
recommended to hold the
arc voltage steady despite
input line voltage varia-
tions. Connection 1n-
structions are shipped
with the Compensator.
the power
source and wire the
power source terminal
strip exactly as shown in
drawing.
AN 4
NS
0———0 | p38-325
©
31
mes ©
32 oO
{+
7
R35-325
0 21 O
2 O R3S-400, 600
- 31 с and 800
o 32 ©
o 4 O
-O-
Connect the electrode cable to the output ter-
minal of polarity required by electrode. Con-
nect work lead to other output terminal.
Set the Control Circuit Switch to “Negative”
or “Positive”, as appropriate.
Set the R3S output controls to the voltage rec-
ommended for the electrode being used.
Place the toggle switch in the “Fine Voltage
Control at R3S” position unless a K-775 re-
mote control is connected to 75, 76 and 77 on
the R3S terminal strip.
SAM Welders
I.
4a.
4b.
Turn off the power source and wire the SAM
terminal strip exactly as shown in this drawing.
The “Portable Field Control” shipped with
SAM welders must be installed. It provides
voltage control at the welding location. Con-
nection instructions are in the SAM Operating
Manual.
Connect the electrode ca-
ble to the “Auto Equip-
ment” stud and the work
cable to the “To Work”
stud.
All SAM-300 & 400
Models Generally,
set the “Electrode Polar-
ity” switch to the con-
stant voltage polarity
required by the elec-
trode.
SAM-500, 600 & 650
Models (engine) — Set
the “Electrode Polarity”
switch to “Negative” or
To Portable Field Contro!
AZ!
67
||
“Positive” as required by the electrodes. Con-
nect the SAM “Tap” lead to the “Innershield”
stud desired.
5. Set the toggle switch to “Constant Voltage.”
. Set the “Constant Voltage Control” and the
“Portable Field Control” on #5 for the initial
start.
C. DC-600 Welder (Turn off the power source)
1. Wire the power source terminal strip exactly
as shown in the drawing. (NOTE: There is no
NPS terminal strip in DC-600’s with codes
above 8200.)
о о оо о о о о о 0
21 4 2 31 32 75 76 77 80 81
o 9 ооо о о о ©o O
|
о о o
N P S
о ©
2. Connect the electrode cable to the output ter-
minal of polarity required by electrode. Con-
nect work lead to other output terminal.
3. Place “Set To Same Polarity As Electrode Ca-
ble Connection” switch at appropriate posi-
tion.
4. Place the toggle switch in “Output Control at
DC-600” position unless a K-775 remote con-
trol is connected to 75, 76 and 77 on the DC-
600 terminal strip.
5. Power Source setting — Set the three toggle
switches on DC-600 per nameplate instruc-
tions. Set output control on “4” to start.
NOTE: For LN-22 codes below 7800 the LN-22 may
not inch if the DC-600 OCV is above 40 volts. For
LN-22 codes above 7800 the LN-22 may not inch if
the DC-600 OCV is above 50 volts. Keep the OCV
below these values.
D. DC-400 Welder (Turn off the power source.)
1. Wire the power source terminal strip as shown
in the drawing.
о о da Y © © o ©
21 4 2 31 32 75 76 77
e e ¢ o © © © ©
2. Connect the electrode cable to the output ter-
minal of polarity required by electrode. Con-
nect work lead to other terminal.
3. Place “Set To Same Polarity as Electrode Cable
Connection” switch at appropriate position.
4. Place the toggle switch in “Output Control at
DC-400” position unless a K-775 remote con-
trol is connected to 75, 76 and 77 on the DC-
400 terminal strip.
5. Power source setting — If unit has a mode
switch, set switch to “Constant Voltage Inner-
shield”. Set output control on “6” to start.
E. DC-250
Connection of LN-22 Wire Feeder to DC-250.
1. Turn off the DC-250 Power Switch.
2. Connect a jumper from 2-4 on terminal strip.
3. Connect the electrode cable to the Innershield/
GMAW/CV output terminal of polarity re-
quired by electrode. Connect the work lead to
the other CV terminal.
4. Place the DC-250 electrode negative-electrode
positive switch to the same polarity as the elec-
trode cable.
5. Place the DC-250 Output Control Switch in the
“at DC-250” position unless a K-775 Remote
Control or Amptrol'M is connected to 75, 76,
77 on the DC-250 terminal strip. If a Remote
Control or Amptrol is used the Output Control
Switch should be placed in the “Output Control
Remote” position.
6. Place the DC-250 Mode Switch to Innershield/
GMAW/CV.
7. Place the DC-250 CV Arc Control Switch to
“17, <2” or “3”. (MIN., NORMAL or MAX.
on some machines.)
F. SAF-600 and SA-800. (Turn off the power source.)
1. Generator connections — Jumper 2 to F4 to
close full field relay. Jumper 2 and 24 to close
field circuit. Machines with contactor only
(“O” models), jumper 2 to 24.
2 Connect electrode lead to INNERSHIELD
stud. Connect work lead to WORK stud.
3. Set “Electrode Polarity” switch to polarity re-
quired by the electrode. Set “Voltage Range”
switch on low. Set the voltage rheostat on “2”
for initial start.
POLARITY
LN-22's with Code 8624 and above are equipped with
a polarity switch. Set polarity switch to the same
polarity as the power source electrode connection.
LN-22's below Code 8624 were shipped internally
connected for welding with electrode negative polarity
[DC(-)]. By interchanging the input leads to the P.C.
board, the unit can be connected to operate with only
positive polarity (required for 5/64” NS-3M) electrodes.
Referring to wiring diagram, disconnect the bolted
connections A and B. Connection A is located in the
control box and connection B is located within the
drive motor case. Connect lead 567 from the P.C.
board to lead 21 coming from the work. Connect lead
21 coming from the P.C. board to lead 567 coming
from the amphenol receptacle on the front of the unit.
Tape up connections and replace covers. Unit will
now operate only with positive polarity electrode.
METERS (Units above code 7800 include meters as a
standard feature.)
|. The LN-22 includes a wire feed speed meter and
an analog voltmeter. This voltmeter has a pointer
which indicates the arc voltage on the meter scale.
2. K-251 (LN-22 codes between 7552 and 7800) 1n-
cludes a wire feed speed meter and an electronic
voltmeter. This voltmeter has red lights which 1n-
dicate when the arc voltage is higher or lower and
a green light to indicate when the arc voltage 1s at
the desired voltage pre-set on the calibrated dial.
A K-263 (LN-22 codes above 8000) electronic volt-
meter is available (as an option) which replaces
the standard analog voltmeter. Installation instruc-
tions (S-15713-1) are shipped with the kit.
GUN AND CABLE ASSEMBLIES
The K-264-8 (rated 250 amps, 60% duty cycle) or the
K-361-10 (rated 350 amps, 60% duty cycle) gun and
cable assemblies can be used with the LN-22. An am-
phenol connector connects the gun trigger control
wires to the front of the LN-22 and a single set screw
fastens the wire feed cable to a brass block on the gear
box assembly.
WARNING: Disconnect the LN-22 input cable or
shut off the welder before changing the gun and ca-
ble assembly. Refer to the following chart for gun
parts.
Electrical
Insulated Guide Stickout | Visible Stickout
S-15900 3/4 to 11/2" ‘/s” less than
(Provided with K-264-8 gun) | °° | electrical stickout
S-17217-1
(Provided with K-361-10 gun) 2” 198”
T-12313 (Thread Protector)
(Provided with both guns)
Same as
3 "” 1 rr"
fa” 10 1/2" | electrical stickout
CONTROL LEAD
Attach the single lead from the LN-22 control box to
the work using the spring clip on the end of the lead.
This is only a control lead — it carries no welding
current.
LOADING THE WIRE REEL
WARNING: The electrode is always electrically hot
when the power source is connected to the LN-22
and turned on. It will arc if it touches the work or
any metals touching the work. When not welding,
store the gun in the insulated tube on the wire reel
housing.
1. With the door closed, connect electrode lead to
wire feeder by means of QD connector and fasten
spring clip on control lead to work.
2. Lay the LN-22 flat with the wire reel cover up
and remove the snap cover. Slide insulator up on
the wire feed cable connected to the reel housing.
3. Remove the center clamping nut and the cover
plate from the wire reel.
4. Unpack the 14-pound coil of wire. Be sure not to
bend the side tangs of the coil liner and straighten
any tangs that may have been bent.
5 Place the coil on the wire reel so the coil will
unwind when it rotates in a clockwise direction.
6. Remove the start end of the coil from its holding
slot in the coil liner, cut off the bent end,
straighten first inch and thread it through the wire
feed cable connected to the cannister until about
six inches of electrode is exposed.
7. Be sure all the lower tangs of the coil liner are
flush against the back half of the wire reel and
that none of the upper tangs are bent in against
the coil.
8. Replace the reel cover plate and the center clamp-
ing nut.
9. Replace the cover of the wire reel housing.
10. Thread the exposed end of the electrode through
wire feed cable connected to the wire drive. Press
gun trigger until electrode hits drive rolls to just
pick up electrode. Do not feed electrode through
cable at this time. Slide insulator down the wire
feed cable until it slips over section of cable con-
nected to gear box.
11. Set the unit upright on floor, press the gun trigger
and feed electrode through gun and cable assem-
bly.
OPTIONAL 50 POUND WIRE REEL (K-276)
Install the reel assembly on the LN-22 to feed .068
through 5/64” Innershield electrode from 50 pound
coils. Installation and reel loading instructions
(M-13153) are shipped with the kit.
OPTIONAL LN-22 CONTACTOR
VOLTAGE CONTROL (K-279-25)
For use with SAM, R3S, DC-250, DC-400 or DC-600
power sources. Provides voltage control at LN-22 and
a “cold” electrode until gun trigger is pressed. In-
stallation instructions are shipped with the kit.
MAKING THE WELD
For LN-22°s above code 8600, check that polarity
switch on back of control box is in correct position.
Be sure the proper contact tip for the wire size to be
used is in the gun. Screw the appropriate contact tip
insulator over the contact tip.
Loosen the insulated screw on the side of the gun,
rotate the gun nozzle to the position most convenient
and retighten the insulated screw.
When welding, set the wire feeder on the floor or hang
it near the work area as convenient. Place the LN-22
to minimize the amount of spatter falling onto it. Al-
ways avoid sharp bends and keep the gun cable as
straight as practical.
Be sure the electrode cable, work cable and control
lead are connected and the power source 1s on.
WARNING: The electrode is always electrically
“hot” when the power source is on and the circuit
is complete.
Press the gun trigger to feed the electrode out of the
gun. Refer to chart for visible stickout.
Position the gun with the wire just off the work. Press
the gun trigger to start the arc. At the end of the weld,
release the trigger and pull the gun away from the
work to stop the arc.
When not welding, always store the gun in the insu-
lated tube on the wire feeder.
ADJUSTING WIRE FEED SPEED AND
VOLTAGE
Set the wire feed speed (current) using the dial on the
back of the LN-22 control box. When establishing
initial procedures, set the dial at about mid-range.
Adjust the dial while welding to obtain the wire feed
speed or current specified in the procedures.
NOTE: Inching speed is different from welding feed
speed at all dial settings.
Set the voltage using the power source controls in-
cluding the remote or portable field controls when
installed. .068” through 6” Innershield® wires op-
erate at 15 to 30 volts. The process of setting voltage
varies depending upon the type of voltmeter installed:
1. If the LN-22 is equipped with the analog volt-
meter, adjust the controls while welding until the
voltage specified in the procedures 1s indicated on
the meter. The meter reading with the power
source on but not welding is the open circuit volt-
age. With both SAM and R3S$ power sources, this
voltage is always significantly higher than welding
voltage.
If the LN-22 is equipped with the electronic volt-
meter, set the dial on the meter for voltage spec-
ified in the procedures. Adjust the power source
voltage controls until the high and low red lights
on the voltmeter remain off and the green light
remains on while welding.
If the LN-22 is not equipped with meters (codes
below 7800), increase the voltage settings while
welding until the proper arc characteristics are ob-
tained. A voltmeter on the power source can be
used, but the voltage readings must generally be
higher than specified in the procedures to supply
the voltage drops in the work connection and work
cable.
When establishing initial procedures, start with the
voltage control set near minimum. Strike an arc on
scrap steel. If the arc fails to start, increase the voltage
settings until the arc can be established.
Remember that changing the power source voltage
setting affects the wire feed speed setting. Changing
the LN-22 wire feed speed setting may affect the volt-
age, but only slightly. Both must be readjusted until
the outputs specified in the procedures are obtained.
NEVER set the power source open circuit voltage
higher than 70 volts (50 volts on DC-600 or other
power sources with a high OCV ripple content). With
SAM and R3S welders, this limit includes the hot start
voltage. The LN-22 will not feed wire when the volt-
age is higher than 70 volts.
WIRE REEL CHANGING
WARNING: Disconnect the electrode QD connector
from the back of the wire feeder so the electrode is
not electrically “hot,” then pull the electrode out of
the gun using pliers. Reload the wire reel as de-
scribed previously.
PORTABILITY
To move to a new location, place the gun in the in-
sulated tube on the wire feeder, disconnect the elec-
trode cable by removing the QD connector from the
back of the wire feeder and disconnect the control
lead from the work and clip it to the LN-22. Then
move the unit to the new location.
MAINTENANCE AND TROUBLESHOOTING
WARNING: Have qualified personnel do the main-
tenance and troubleshooting work. Turn the input
power off by disconnecting the electrode cable QD
connector from the back of the wire feeder before
working inside the machine.
A. Replacing or Reversing Drive Rolls (See Drawing
below).
1. Remove the idle roll tension screw (item 17)
and set screw (item 14) which holds pivot pin
(item 12) in place.
2. Remove pivot pin (item 12) and slide out 1dle
roll assembly (see “B” below).
3. Remove hex head screw (item 3) and the drive
clamping collar (item 4).
4. Remove drive rolls and spacer from shaft.
5. Wipe the drive roll and spacer surfaces clean.
Install one drive roll, then the spacer, and the
second drive roll. If reversing drive rolls, turn
drive rolls over so unworn teeth face each
other.
6. Replace clamping collar and hex head screw.
7. Replace idle roll assembly, pivot pin, set screw,
tension spring, washer and tension screw. This
screw should be tightened completely, then
back out two turns.
B. Removing Idle Roll Assembly
1. Remove idle roll tension screw (item 17) and
set screw (item 14) which holds pivot pin (item
12) in place.
2. Remove pivot pin and slide out idle roll assem-
bly.
3. To re-assemble, replace idle roll assembly, pi-
vot pin, set screw, tension spring, washer and
tension screw. This screw should be tightened
completely, then back out two turns.
C. Gun and Cable Maintenance
Gun Nozzles (All):
1. Replace worn contact tips as required.
2. On Innershield guns, remove spatter from tip
or extension guide after each ten minutes of
arc time or as required.
3. Replace worn spring liners in nozzles. The life
of the liner can be doubled by rotating liner
180°. The liner can be pulled out of the back
end of the nozzle by wedging the blade of a
small screwdriver in the I.D. and pulling.
4. Internal parts of nozzles can be removed and
replaced by removing the internal hollow-lock
set screw from the contact tip end of the nozzle
with a 532 or 316” Allen wrench.
The insert and retainer will normally fall out the end
of the nozzle but if they do not, gently drive the spring
liner towards the outgoing end of the nozzle.
See appropriate parts list page for construction details
and replaceable parts. For those guns where similar
nozzles are used for different wire sizes, note the iden-
tifying wire size that is stenciled or molded in an area
close to the incoming end. When re-assembling noz-
zle, make certain the ceramic nozzle insert (if used)
is placed next to the spring liner. The hollow-lock set
screw is to be tightened to give the dimension spec-
ified below as measured from the end of the nozzle
to the hollow-lock set screw.
Gun “A”
K-264 ‚38
SPRING LINER
K-361 ‚38 — — SPRING LIN
l__— CERMANIC INSERT
A # INSERT RETAINER
HOLLOW-LOCK SET SCREW
Gun Cables:
1. A dirty gun cable can cause rough and erratic
wire feeding. Therefore, the cable liner must be
cleaned approximately every 300 pounds of
electrode.
Remove the cable from the wire feeder. Lay 1t
out straight on the floor. Remove the contact
nozzle tip from the gun. Using an air hose and
only partial pressure, gently blow out the cable
from the gun end.
Work the full length of the cable by bending 1t
back and forth and then blow it out again. Re-
peat this procedure until no more dirt comes
out.
D. Wire Drive Assembly Maintenance
1. Every 500 pounds of electrode, the drive roll
section should be inspected and cleaned out if
necessary. Do not use a solvent for cleaning
the idle roll as it may wash lubricant out of the
bearing.
. Replace drive rolls as required. Drive rolls 1. Motor won’t a. Fuse on welder blown.
should be worn on both reversible sides before run. Replace fuse.
replacing. b. Grounding lead protec-
. Check the motor brushes every six months. Re-
place if they are less than !/4” long.
. Every year examine the gear box and paint the
gear teeth with graphite grease.
tor tripped. Reset switch
in option control box.
c. Control cables not con-
nected properly. Refer
to instructions.
d. Faulty transformer or
E. Troubleshooting relay in K-279. Replace
faulty parts.
1. Motor won’t a. Circuit breaker tripped.
run. b. 0 y o above 70 vols 2. Can’t obtain a. On SAM welders, con-
( Я volts la -600) — required volt- stant voltage control
о uce vo lage. age. must be adjusted to give
c. Wrong polarity — set required voltage and
polarity switch on units mode switch must be set
above Code 8600 to to constant voltage posi-
same polarity as elec- tion.
trode cable connection. b. On R3S welders, fine
On older units, use neg-
ative polarity or inter-
nally reconnect the LN-
22.
. Faulty control circuit.
e. Faulty gun trigger or
broken control wires.
f. Control lead not con-
nected to work.
. Electrode lead not con-
nect to unit.
. Wire will not
feed, or erratic
. Loop of wire caught on
bent tang in wire reel.
voltage control switch
must be set to remote
position.
c. Defective rheostat in K-
279 control box. Re-
place rheostat.
F. Checking P.C. Board
1.
Connect unit to any Lincoln welder recom-
mended for LN-22 or some DC supply with
three amperes capacity. Any DC voltage from
feeding. b. Worn drive rolls. 20 to 59 volts can be used to check out unit.
c. Welding outside the The DC supply voltage must have a low ripple.
range of unit. For example: the unit may not function prop-
d. Loose nut on drive roll. erly on unfiltered, single phase, full wave, rec-
e. Dirty gun cable. tified AC above 30 volts.
. Erratic arc ac- a. Worn contact tip. 2. Measure voltage between leads 21 and 567 or
tion. 467 on units with polarity switch, with trigger
actuated. This should be same as power supply
. No current a. Faulty printed circuit voltage and lead 21 must be of positive polarity.
control. board or faulty rheostat. If no voltage is measured, trigger is faulty or
unit is not connected properly.
6 tion of ae a ce roll tension too 3. Next measure voltage leads 539B and 541. This
trode causing Ses Sec tion B of “Main- voltage should be between 2 and 14 volts with
wire feed prob- tenance and Trouble- 20 — 59 volts at input. This voltage should
lems hooting” f change with rheostat position. If not function-
` shooting lor proper ing, replace printed circuit board.
setting of tension screw.
4. If P.C. board is working and motor doesn’t run,
the circuit breaker may be tripped or faulty, or
motor needs repairs.
Additional troubleshooting when K-279 contactor
voltage option is used:
GENERAL ASSEMBLY
IRE REEL
MEUNTimG DETAL
G-1612
10-1-82K
— 10 -
Parts List P-115-C
NO. NO.
ITEM PART NAME & DESCRIPTION REQ'D | |ITEM PART NAME & DESCRIPTION REQ'D
1 Frame Assembly 47 Round Head Screw 2
3 Lead Grommet 50 Plain Washer 2
5 Front Panel Lock Washer 2
6 Rear Panel Hex Nut 2
7 Gear Box Cover 51 Gun Holder Clamp 1
10 Control Box, Includes: 52 Gun Support Tube (Below Code 7700) 1
Potentiometer 52 Gun Holder Assembly (Code 7700 to 8700) 1
Knob 52 Gun Holder (Above Code 8700) 1
Circuit Breaker *53 | Cover Panel — Without Meters 1
Insulation *53AV| Analog (With Dial) Voltmeter (Code 7552)
Decal thru 7708) Includes: 1
Toggle Switch (Above Code 8623) (Analog) Voltmeter 1
Nameplate (Above Code 8623) Speedmeter 1
Sems Screw Meter Guard 1
11 Control P.C. Board
P.C. Board Insulation
Sems Screws
Wire Feed Speed Meter (Code 7552
thru 7708) Includes:
"S3WF Electronic D.C. Voltmeter
12 Ground Clamp
13 Door & Base Plate Assembly
14 Control Box Cover, includes:
Speedmeter
Meter Guard
*53EV | Electronic (With Lights) Voltmeter
—t — —
Decal (“Electrode May Not Feed . . .”)
Warning Label
Speedmeter
(Above Code 8565)
Electronic D.C. Voltmeter
57 Cover Retaining Strap
Voltmeter (Code 8565 & Above)
Self Tapping Screw
16 Lead Grommet
58 | Wire Feed Cable (Above Code 7700 Only)
59 Hex Head Screw
60 Lock Washer
Nd |r| mma aaa | para [Nm Ad Aa | AA | A
17 Nameplate 61 Plain Washer
Self Tapping Screw 62 Insulating Washer
18 Wire Feed Unit See P-115-D 63 Plain Washer
19 Gear Box Bracket 1 64 Hex Head Screw
Gear Box Insulation 1 Insulator
21 Grommet 1 insulator
22 Gun and Cable Assembly See P-103-N Plain Washer
23 Connector Lock Washer
Self Tapping Screw Hex Nut
24 Receptacle 65 Thread Cutting Screw
Connector Insulator 66 Lead Clamp
26 Round Head Screw Sems Screw
Lead and Coupling Plug Plain Washer
28 Wire Feed Cable Retainer Hex Nut
29 Support Washer 67 Meter Guard Assembly
Mounting Bracket
Sems Screw
30 Wire Feed Cable
69 Mounting Bolt Insulation
70 Hex Head Screw
Lock Washer
Plain Washer
Insulating Washer
Insulating Tube
31 Housing Cover
Trademark Decal on Cover
32 Wire Reel Housing
33 Axle
35 Axle Housing
36 Wire Reel
Insulation
71 Sems Screw
72 Flat Head Screw
37 Wire Reel
39 Axle Insulating Washer
Counter Sunk Lock Washer
73 Self Tapping Screw
Ls > | 4 | PORO | POR | AA a | AN | alas | A | Aa
dd A Ar | AAA) ADN | AAA NAAA
40 | Spring
47 Axle Nut
50 Gun Holder Bracket (Below Code 8700)
Sealing Panel
WHEN ORDERING GIVE: Item No., Part Name,
Parts List No., and Welder Code.
— 11 -
WIRE DRIVE MECHANISM
| Le)
\ _ A
5 23) - -
Ee, - A)
--— se | A T _ _- > |
74 ; ‘ ee) |
WHEN ORDERING GIVE: Item No., Part Name,
Parts List No., and Machine Code No.
2 | Ш e 8710
— с НН )
[ NANA
| CN 7 =
— = = WT
to La
J (J
13
| |
| b o
AN LY FLY LT IZ]
L-5456
7-23-82P
WHEN ORDERING GIVE: Item No., Part Name,
Parts List No., and Welder Code.
Parts List P-115-D
NO. NO.
ITEM PART NAME é DESCRIPTION REQ'D | {ITEM PART NAME & DESCRIPTION REQ'D
Wire Feed Assembly, Includes: 1 11 Socket Set Screw 2
1 Drive Motor and Gear Box, Includes: 1 13 Conductor Block Insulation 1
Gear Box 1 14 Socket Set Screw 1
Drive Motor, Includes: 1 15 Pivot Pin 1
Pinion Gear 1 16 Idle Roll Assembly 1
Roll Pin 1 18 Spring 1
Brush & Spring 2 20 Incoming Guide Tube” 1
Brush Cap 2 21 Idle Roll Pull Arm 1
2 Drive Roll* 2 22 Spacer” 1
3 Sems Screw 1 23 Locator Bushing 1
4 Collar 1 25 Outgoing Guide Tube Insert” 1
5 Key 1 26 Idle Roll Arm Bracket 1
6 Socket Set Screw 1
7 Outgoing Guide Tube" 1
8 Conductor Block 1 Drive Roll & Guide Tube Kit (Includes
9 Insulating Bushing 2 * Parts Shown)
10 Insulating Washer 2 1
— 12 -
K-279 CONTACTOR-VOLTAGE CONTROL
RIGHT SIDE VIEW
TOP VIEW
WHEN ORDERING GIVE: Item No., Part Name,
Parts List No., and Welder Code.
L-6966
1-6-84B
Parts List P-115-E Parts List P-115-E
NO. NO.
ITEM PART NAME & DESCRIPTION REQ'D ITEM PART NAME 8: DESCRIPTION REQ'D
11 Transformer
1 Control Box Cover 1 Round Head Screw
Self Tapping Screw 6 Lock Washer 1
2 | Control Box Case 1 Hex Nut 2
3 Thread Forming Screw (Grounding Screw) 1 12 Gun Cable Assembly, Includes: 1
Lock Washer 1 Cable Connector 1
Hex Nut 2 Cable Clamp 1
4 | Grounding Lead Protector Assembly, Includes: 1 13 | Chain (Code 7809 Oniy) (Not Illustrated) 1
Micro Switch 1 Wire Feeder Cable Assembly, Includes: 1
Round Head Screw 2 14 Cable Connector 1
Lock Washer 2 Cable Clamp 1
Hex Nut 2 15 | Capacitor Assembly 1
5 Nameplate 1 Clamp 1
Self Tapping Screw 3 Round Head Screw 1
6 Connector Leads & Potentiometer Assembly, 1 Plain Washer 1
Includes Lock Washer 1
Cable Connector 1 Hex Nut 1
Potentiometer 1 16 | Clamp 1
Self Tapping Screws 4 Round Head Screw 1
7 Potentiometer Insulation 1 Lock Washer 1
8 | Potentiometer Knob 1 Hex Nut 1
9 Cable Strain Relief 1
10 Contactor Relay (Above Code 8800) 1
Round Head Screw 2 Items Not Illustrated:
Plain Washer 2 Control Cable, Includes: 1*
Lock Washer 2 Input Connector 1
Hex Nut 2 Cable Clamp 1
* Specify Length
- 13 -
K-264 & K-361 SQUIRTGUN AND CABLE
A hs a TR
SECTION THRy NOZZLE CLAMP &
CABLE CONMECTOR
Parts List P-103-N for Cable Assembly
Note: Gun manufactured after 6-1-76 use a new
design reverse bend nozzle, new type contact tip
and nose cone assembly. These parts are called
for in the parts list. Old design guns may be up-
dated to this new design by ordering items 8, 10
and 13. If old nozzle is in satisfactory condition,
S-13961-068 or -5/64 contact tips and T-13023
Do | nose cone assembly may still be purchased.
Noz zle fo
insert
Insert (09
retainer
Locking
screw
rr 77 Era
|] О
TIP A A
NAAM Veo
>
NAN
>.
LUE o contact
UH tip L-5457
10-8-82B
WHEN ORDERING GIVE: Item No., Part Name,
Parts List No., and Gun.
TRIGGER AND CONTROL
CABLE ASSEMBLY
Parts List P-103-K for Cable Assembly
NO.
ITEM PART NAME & DESCRIPTION REQ’D
Trigger and Control Cable Assembly,
Includes:
Micro-Switch
Switch Pad
Trigger Assembly
Cord Clamp
Coil Spring
Roll Pin
Roll Pin
Insulation Sleeving
Set Screw
O 60 | MOI IA | WN
A N | PN | Aa | m
nk
N
Polarized Plug, Wire Feeder End, Not
lilustrated
12A Clamp at Polarized Plug
— —
NO.
ITEM PART NAME & DESCRIPTION REQ’D
Gun and Cable Assembly, Includes: 1
1 Handle 1
2 Conductor Cable 1
3 Retaining Ring 1
4 Clamp 1
5 Spatter Shield 1
6 Pan Head Screw 3 or 4
7 Hand Screw Assembly 1
8 Contact Tip (5/64 Wire) See Note 1 *
9 Contact Tip (.068 & .072 Wire) *
10 50°/70° Nozzle Assembly 1
10 90° Nozzle Assembly 1
10 30° Nozzle Assembly — Std. Length 1
10 30° Nozzle Assembly — 6” Longer than
Std. Length
10A 50°/70° and 30° Nozzle Liner — Std. Length 1
10A 30° Nozzle Liner — 6” Longer than 1
Std. Length 1
10B Nozzle Insert 1
10C Nozzle Insert Retainer 1
10D Liner Locking Screw 1
11 Trigger & Control Cable Assembly 1
Assembly Parts See P-103-K
12 Clamp 1
13 Nose Cone Assembly 1
14 Heat Shield Assembly 1
15 Gun Caution Decal 1
16 Thread Protector 1
17 Round Head Screw 1
18 Round Head Screw 2
Lockwasher 2
Hex Nut 2
19 Switch and Cable Assembly, Includes: 1
Switch 1
Switch Boot 1
Note 1: When tip life is limited by tip being fused
over, T-14726-5/64 Tips may give a lower
overall cost.
As Required.
5-14-82U
_ 14 —
K-276 50 AND 60# WIRE REEL SUPPORT
FULL SITE DETAIL
SHOWING INSJL MIG
(3 PLACES)
Go)
+4
ss A
415 ?Yal3 +
41516171815 |
L-4699
11-14-75E
WHEN ORDERING GIVE: Item No., Part Name,
Parts List No., and Welder Code.
Parts List P-107-0
NO.
ITEM PART NAME 8 DESCRIPTION REQ'D
LN-7 Wire Reel Support Assembly, Includes:
Wire Reel
Wire Reel Housing
Reei Support
Plain Washer
Lock Washer
Hex Nut
Hex Head Screw
Insulating Washer
Insulating Tube
Reel Mounting Shaft Assembly
Cable Clamp
Thread Cutting Screw
Insulating Tube
Optional Door Assembly, Includes:
Door and Hinge Welded Assembly
Catch
Sealing Panel
Sealing Panel Mounting Plate
XNE-LN Lightweight Wire Reel Support
Assembly Includes:
Wire Reel
Hand Crank Assembly
—
OO®D/ NO | BOM|—
— 4 A
N —
—
pus | = — — | по № = | — —® № | VOGOOOHA|—+0
Cage Type Wire Reel Support
Wire Feed Unit Handle
Reel Mounting Shaft Assembly
(For 2” 1.D. Spools)
Reel Mounting Shaft Assembly (Standard)
— — — — «=
— —
_ 15 -
HOW TO ORDER REPLACEMENT PARTS
Order parts only from Lincoln offices or from the Authorized
Field Service Shops listed inthe “Service Directory”. Give the
following information;
(a) From the nameplate — machine model, code and serial
numbers.
(b) From this manual — complete part name and descrip-
GUARA
The Lincoln Electric Company, the Seller, warrants all new
equipment except engines and accessories thereof against
defects in workmanship and material for a period of one year
from date of shipment, provided the equipment has been
properly cared for, and operated under normal conditions.
Engines and engine accessories are warranted free from
defects for a period of ninety days from the date of shipment.
If the Buyer gives the Seller written notice of any defects |
provided Buyer herein for breach of Seller's
exclusive.
World's Largest Manufacturer of Arc Welding Products -*
tion, item number, quantity required and the number of
the list used to get this information.
Any items indented in the “Parts Name” column are included
in the assembly under which they are listed. The indented
items may be ordered separately. If the entire assembly is
needed, do not order the indented parts.
A
eine defects#i the equipment or replacing defective
N rode in accorglince with the above guarantee. Upon the
irati
mate.
ng guarantees and remedies are exclusive and
» above set forth. There are no guarantees or war-
limitation the warranty of merchantability, all such warran-
ties being waived by the Buyer.
Manufacturer of Industrial Motors
ост THE LINCOLN ELECTRIC COMPANY
ELECTRIC |,
Sales and Service Worldwide
Toronto M4G 2B9 — Canada .
Eff. March '87
Cleveland, Ohio 44117-1199 U.S.A.
Rouen 76120 — France
Litho in U.S.A.
Sydney 2211 — Australia °
5-84