Professional Documents
Culture Documents
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.
SERVICE MANUAL
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View Safety Info
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View Safety Info
WARNING
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
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not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. 2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
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LT-7 TRACTOR
ii SAFETY ii
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically hot when the welder is on. plates to protect your eyes from sparks and
Do not touch these hot parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
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5.d. 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.
LT-7 TRACTOR
iii SAFETY iii
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing through 8.b. Install equipment in accordance with the U.S. National
lifting chains, crane cables or other alternate circuits. This can Electrical Code, all local codes and the manufacturers
create fire hazards or overheat lifting chains or cables until recommendations.
they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturers recommendations.
6.I. Read and follow NFPA 51B Standard for Fire Prevention
During Welding, Cutting and Other Hot Work, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
LT-7 TRACTOR
iv SAFETY iv
Sret Pour Soudage A LArc 8. Sassurer que la masse est connecte le plus prs possible de
1. Protegez-vous contre la secousse lectrique: la zone de travail quil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dautres endroits
a. Les circuits llectrode et la pice sont sous tension loigns de la zone de travail, on augmente le risque de voir
quand la machine souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue cbles de grue, ou autres circuits. Cela peut provoquer des
ou les vtements mouills. Porter des gants secs et sans risques dincendie ou dechauffement des chaines et des
trous pour isoler les mains. cbles jusqu ce quils se rompent.
b. Faire trs attention de bien sisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particulirement important pour le soudage de tles
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les positions assis ou couch pour lesquelles une grande galvanises plombes, ou cadmies ou tout autre mtal qui
partie du corps peut tre en contact avec la masse. produit des fumes toxiques.
c. Maintenir le porte-lectrode, la pince de masse, le cble de
soudage et la machine souder en bon et sr tat defonc- 10. Ne pas souder en prsence de vapeurs de chlore provenant
tionnement. doprations de dgraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-lectrode dans leau pour le chaleur ou les rayons de larc peuvent ragir avec les vapeurs
refroidir. du solvant pour produire du phosgne (gas fortement toxique)
e. Ne jamais toucher simultanment les parties sous tension ou autres produits irritants.
des porte-lectrodes connects deux machines souder
parce que la tension entre les deux pinces peut tre le total 11. Pour obtenir de plus amples renseignements sur la sret, voir
de la tension vide des deux machines. le code Code for safety in welding and cutting CSA Standard
f. Si on utilise la machine souder comme une source de W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-lectrode sapplicuent aussi au pistolet de
soudage.
contre les chutes dans le cas ou on recoit un choc. Ne jamais LES MACHINES SOUDER
enrouler le cble-lectrode autour de nimporte quelle partie du
corps.
TRANSFORMATEUR ET
REDRESSEUR
3. Un coup darc peut tre plus svre quun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropri ainsi 1. Relier la terre le chassis du poste conformement au code de
quun verre blanc afin de se protger les yeux du rayon- llectricit et aux recommendations du fabricant. Le dispositif
nement de larc et des projections quand on soude ou de montage ou la piece souder doit tre branch une
quand on regarde larc. bonne mise la terre.
b. Porter des vtements convenables afin de protger la peau
de soudeur et des aides contre le rayonnement de larc. 2. Autant que possible, Iinstallation et lentretien du poste seront
c. Protger lautre personnel travaillant proximit au effectus par un lectricien qualifi.
soudage laide dcrans appropris et non-inflammables.
3. Avant de faires des travaux linterieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont mises de larc de er linterrupteur la boite de fusibles.
soudage. Se protger avec des vtements de protection libres
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de lhuile, tels que les gants en cuir, chemise paisse, pan- 4. Garder tous les couvercles et dispositifs de sret leur place.
talons sans revers, et chaussures montantes.
LT-7 TRACTOR
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Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
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machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
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Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
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g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
LT-7 TRACTOR
Return to Master TOC vi SAFETY vi
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturers recommen-
dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
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Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
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_________________________
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1 Portions of the preceding text are contained in EN 60974-10: Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.
LT-7 TRACTOR
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
LT-7 TRACTOR
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Product Summary
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
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LT-7 TRACTOR
A-2 PRODUCT OVERVIEW A-2
Specifications
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Specifications
VOLTAGE INPUT AMPERES
120VAC 5A
Physical Dimensions
(Overall Size and Weight Dependent Upon Configuration)
K227-1 27.5 Inches (699mm) 33 Inches (838mm) 14 Inches (356mm) 120 Lbs. (54 kg)
K395-1 130 Lbs. (59 kg)
Temperature Ranges
OPERATING TEMPERATURE STORAGE TEMPERATURE
SAW
GEARING WIRE FEED SPEED Range Wire Sizes
LT-7 TRACTOR
A-3 PRODUCT OVERVIEW A-3
PRODUCT SUMMARY
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FEATURES
LT-7 Tractor feeds 3/32 to 3/16 (2.4 to 4.8 mm) solid wires, from 35 - 400 inches per minute (0.9 - 10.2
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Calibrated tractor drive adjusts travel speeds from 6 to 70 inches per minute (0.12 to 1.8 m/min).
Vertical head lift adjuster for adjusting electrical stickout from 1/2 in. to 5 in. (12.7 to 127.0 mm).
Weld angle is up to 50 from vertical on either side; drag angle is up to 30 from vertical.
Control box is conveniently located on the tractor (can be mounted either left or right), eliminating the
need to return to the power source for routine procedure changes.
Exceptional tracking control and self-steering in most applications leave the operator free for quality con-
trol, joint cleaning and flux handling.
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Capable of doing butt joints, horizontal fillets and lap joints to either the left or right side of the tractor
frame.
Close mechanical alignment between wire and joint maximizes weld quality with no fixturing costs.
LT-7 TRACTOR
A-4 PRODUCT OVERVIEW A-4
RECOMMENDED PROCESSES
Submerged Arc (SAW) - DC+ or DC up to 600 amps (1100 amps with water cooling).
Tiny Twinarc.
Process Limitations
The LT-7 Tractor does not support open arc procedures.
REQUIRED EQUIPMENT
Cables
Connects the LT-7 to power sources that have a 14 pin MS type connector (i.e.CV 655, DC 655 or DC 600)
May be required for applications where the LT-7 is a long way from the power source, or for long weld
applications. Extensions may be combined for a total of 200 ft. (60.8m).
K1842-35 - 35 ft. (10.6m) - Weld Power Cable - lug to lug, 3/0, 600A,60% duty cycle
K1842-60 - 60 ft. (18.2m)
K1842-110 - 110 ft. (33.5m) - Weld Power Cable - lug to lug, 4/0, 600A,60% duty cycle
For connecting to power sources with terminal strips and no 14 pin connector (i.e. DC 1000 od DC 1500).
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K1798
LT-7 TRACTOR
A-5 PRODUCT OVERVIEW A-5
K231
K148
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K149
LT-7 TRACTOR
A-6 PRODUCT OVERVIEW A-6
RECOMMENDED GENERAL
OPTIONS
Right Side
K232 - Horizontal Fillet and Lap Adapter Fillets
Kit
Includes a rear guide wheel, and a head tension
spring and front guide wheel assembly on an
adjustable arm which rides in the joint to maintain
alignment and electrode angle.
LT-7 TRACTOR
A-7 PRODUCT OVERVIEW A-7
*
*
*
OPTIONS
*
K277-1 - Tiny Twinarc Adapter Kit for Butt
Seams
K227-2 - Tiny Twinarc Adapter Kit for Flat
Fillets
LT-7 TRACTOR
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NOTES
LT-7 TRACTOR
A-8
Return to Master TOC B-1 TABLE OF CONTENTS - INITIAL SET UP SECTION B-1
LT-7 TRACTOR
B-2 INITIAL SET UP B-2
Travel Control
(both sides)
Clutch Handle
Drive Wheel
Control
Travel Speed
Switch
START
70
60
Direction
105
50
STOP
40
05
LT-7 TRACTOR
15
20
30
0
VOLTS
DC LINCOLN WELD
SOLID STATE
REVERSE
01
04
DC
20
30
Travel Switch
VOLTAGE DOWN
FORWARD
INCH
OF TRAVEL
DIRECTION
CURRENT
INCH
UP
MANUAL TRAVEL
Box
OFF
0
AMPERES
DC
01
AUTOMATIC TRAVEL
2
4
6
8
Travel Control
Code No.
POWER
ON
CONTROL
Box
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO, MADE IN U.S.A.
Code No. ON
CONTROL
6
AUTOMATIC TRAVEL
4 Serial No. OFF
POWER
8
OFF DC
AMPERES
10
0
Travel Switch
MANUAL TRAVEL
DIRECTION INCH
CURRENT UP
OF TRAVEL
FORWARD
INCH
VOLTAGE DOWN
Direction
30
REVERSE 20
DC
10
40
20 DC LINCOLN WELD
15 30
Switch
VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
60
5 70
START
Travel Speed
Control
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Front
Travel Motor Guidance
and Gear Box Assembly
Drive Wheel
Clutch Handle
(both sides)
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1. Travel Control Box - Contains the circuitry and controls to set travel direction and travel speed.
Travel Switch - The MANUAL position is used for positioning. The AUTOMATIC position starts and
stops the travel with the weld control switches. The OFF position prevents travel.
2. Travel Motor and Gear Box - Provides for the movement of the LT-7 as directed by the Travel Controls.
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3. Drive Wheels - Mounted on the rear axle which is gear driven by the Travel Motor.
4. Clutch Handle - Engages or disengeges the drive gear on the rear axle to allow for normal drive or free-wheel-
ing.
5. Front Guidance Assembly - Can be mounted in various positions to provide proper support, steering and
tracking. See Figure B.4.
LT-7 TRACTOR
B-3 INITIAL SET UP B-3
Control
Strain Relief
Input Cable
Assembly
(under cover) Contact Nozzle
Reed Switch
Shunt and Shield
Lower Coil
Wire Reel and Flux Hopper
Wire Feed Head
Take-off Arm
Electrode
Insulated
Assembly
Wire Guide Head Mounting
Nylon 70
START
60
STOP
105
50
05
LT-7 TRACTOR
15 30
40
20
0
VOLTS
DC LINCOLN WELD
SOLID STATE
DC
20
30
04
VOLTAGE DOWN
FORWARD
INCH
MANUAL TRAVEL
OFF
0
AMPERES
DC
01
Box
AUTOMATIC TRAVEL
2
4
6
8
Code No. ON
CONTROL
POWER
Control
4
6
Code No.
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO, MADE IN U.S.A.
ON
CONTROL
POWER
Box
AUTOMATIC TRAVEL Serial No. OFF
8
OFF DC
AMPERES
10
0
MANUAL TRAVEL
FORWARD
INCH
VOLTAGE DOWN
30
REVERSE 20
DC
10
40
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
Nylon
STOP
60
5 70
START
Insulated
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Electrode
Take-off Arm
Wire Feed Head
Wire Reel and Flux Hopper
Lower Coil
Shunt and Shield
Reed Switch
(under cover) Contact Nozzle
Assembly
Input Cable
Strain Relief
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1. Control Box - Contains the circuitry, controls and meters for adjusting and monitoring of the weld parameters.
See Figure B.3 for more detailed information
2. Wire Feed Head - Drives the weld wire as directed by the Control Box. (See Figure B.5).
3. Head Mounting Assembly - With the Vertical and Horizontal adjusters, allows for positioning of the Wire Feed
Head. (See Figure B.7).
4. Flux Hopper - Feeds flux to the nozzle at a rate determined by the Manual Flux Flow Valve. See Figure B.6.
7. Reed Switch - Monitors the fact that weld current is present and relays that information to the Logic Board.
8. Insulated Takeoff Arm - Provides a path for the electrode through the Nylon Wire Guide to the Feed Head.
9. Nylon Wire guide - Prevents the electrode from touching any part of the LT-7 framework.
LT-7 TRACTOR
B-4 INITIAL SET UP B-4
(CC is shown)
START
70 Nameplate (2)
60
105
50
STOP
40
05
LT-7 TRACTOR
15
20
30
0
VOLTS
DC LINCOLN WELD
SOLID STATE
01
DC
REVERSE 20
Controls
04
30
VOLTAGE DOWN Welding
FORWARD
INCH
OF TRAVEL
Box
DIRECTION
CURRENT
INCH
UP
Travel
0
AMPERES
X100
01
OFF DC
AUTOMATIC TRAVEL
2
4
8
6
Serial No. OFF
POWER
Code No. ON
CONTROL
Switch
Meters THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO, MADE IN U.S.A. Power
Meters THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO, MADE IN U.S.A. Power
Code No. ON
CONTROL
Switch
6 POWER
AUTOMATIC TRAVEL
4 Serial No. OFF
Travel
8
2
OFF DC
AMPERES
Control
10
0
X100
MANUAL TRAVEL
Box INCH
DIRECTION
CURRENT UP
OF TRAVEL
FORWARD
VOLTAGE
INCH
DOWN Welding
30
20
REVERSE Controls
DC
40
10
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
60
5 70 Nameplate (2)
START
(CC is shown)
Control Box
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Mounting
Travel Motor
Cable Wire Feed
Motor Cable
To Shunt Box
Input Cable
Connector
2. VOLTMETER - Shows actual voltage (both OCV and weld volts) after the START button is pressed.
4. INCH DOWN Button - Provides forward feed of wire through the feed head and Contact Nozzle.
CAUTION
DO NOT HOLD THE WELDING WIRE WITH BARE HANDS WHILE INCHING DOWN
When Inching Down, a low voltage signal is applied to the weld wire to enable the Auto Stop Circuit.
7. Upper Welding Control - Controls the output of the power source. In CC Mode, it controls the Current and
in CV Mode it controls the Voltage.
8. Lower Welding Control - Controls the Wire feed Speed. In CC Mode it controls the Voltage and in CV Mode
it controls the Current.
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9. Nameplate - There are two (2) nameplates provided. The CC (VV) Operation is shown in Figure B.3, The CV
nameplate is mounted behind the VV nameplate
NOTE: The CV nameplate labels the upper control as VOLTAGE, and the lower control as CURRENT (See
Figure E.6). The functions of the controls are as indicated above.
10. Input Cable Connector - accepts the control cable from the power source.
LT-7 TRACTOR
B-5 INITIAL SET UP B-5
Clamp Arm
Housing
Clamp Arm
Right Side of
Wheel on
Steering Wheel
Bolts
Adjustment
Steering
Clamp Arm
Left side of
Wheel on
Steering Arm
Steering Wheel
Housing Steering Arm
Right Side of
Methods in Section C of this manual. Clamp Arm
FIGURE B.5
WIRE FEED HEAD COMPONENTS
Assembly
Feed Head
Insulated Handle
Straightener Mounting and
Wire Flux Hopper
Wire
and wire drive mechanism for feeding 3/32 through Straightener Mounting and
3/16 electrode. Insulated Handle
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LT-7 TRACTOR
B-6 INITIAL SET UP B-6
Flux Tip
Mounting Holes
Flux Hopper
Hopper
Flux
Flow valve
Manual
Flux Tip
Mast
45
Adjust
Vertical
Screw
Locking
Assembly
Cross Seam
Block
Clamp
Barrel
Pivot Plate
Adjuster
Cross Seam
Vertical
Adjust
2. Vertical Adjust - Provides fine adjustment for prop-
Mast
er electrical stickout.
30
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Pivot Plate
Screw Barrel
6. Pivot Plate Barrel - Mounts the Feed Head to the
Clamp Block. It allows the head to be rotated to
change the electrode angle.
LT-7 TRACTOR
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Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
LT-7 TRACTOR
C-2 ASSEMBLY C-2
GENERAL INFORMATION
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Items shipped loose that may or may not be required for a par-
ticular weld application are:
This section will aid in setting up the LT-7 Tractor with various
Contact Nozzle Assemblies and optional kits for performing dif-
ferent weld applications (butt welds, fillet welds and lap welds).
It will also cover methods of steering and tracking.
LT-7 TRACTOR
C-3 ASSEMBLY C-3
Tools Required
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91
m
m
3
4/
3/
4
19
m
m
9/16-inch (Preferred) or 3/4-inch (Preferred) or
15 mm Combination Wrench 19 mm Combination Wrench
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CAUTION
All Hardware is English. If using Metric tools, be careful not to round off the corners of the hardware.
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Sockets and a ratchet can be used to access most of the hex head hardware items.
LT-7 TRACTOR
C-4 ASSEMBLY C-4
KP1962-x KP2100-3
Adapter
KP1992-1
Flux Cone
Tips
Contact
Copper Tip
Body
Flux Cone
Flux Tube
Wing Screw
Connection
Screw Weld Cable
Socket Head
Socket Head
Screw Weld Cable
Connection
Wing Screw
Flux Tube
Flux Cone
Body
Copper Tip
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Contact
Tips
Flux Cone
KP1992-1
Adapter
KP1962-x KP2100-3
K231-1 CONTACT NOzzLE Connect the end of the Flux Tube assembly to the bot-
tom of the flux hopper. Fit the copper tip into the hole in
Use the K231-1 for submerged arc welding using cur- the flux cone body. See Figure C.1
rents generally under 600 amps. Higher currents can be
used but result in somewhat faster tip wear. CAUTION
The outer flux cone deposits flux around the arc for full Do not push the copper tip fully into the flux cone
coverage with minimum flux consumption. body. It may cause an electrical short between the
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NOTE: In other systems, K231 nozzles used for 3/32 OPERATION - DO NOT completely straighten the elec-
(2.4 mm) electrode use a liner and a contact tip trode. A slight curvature is required in the electrode to
adapter. insure good electrical contact inside the contact tip.
DO NOT USE THE LINER WITH THE LT-7. MAINTENANCE - Replace the contact tip when it no
longer provides accurate wire location or good electrical
Screw the adapter into the end of the nozzle contact. Rusty and dirty wire or excessively high cur-
and the contact tip into the adapter. (See Figure rents increase tip wear. Always keep replacement tips
C.1). in stock.
INSTALLATION
nut and remove the flux cone. Then unscrew the tip and
Insert the outgoing wire guide from the wire feed head replace it.
into the top of the nozzle and install the nozzle in posi-
tion on the bottom of the wire feed head. Lock it in posi- A special socket head screw holds the nozzle body to
tion using the two clamps provided with the head. the insulator. If the nozzle body becomes loose, remove
the nozzle from the head, tighten the screw and
reassemble nozzle.
LT-7 TRACTOR
C-5 ASSEMBLY C-5
Contact Tip
Connection
Weld Cable
Assembly
Guide Tube
Guide Tube
Assembly
Weld Cable
Connection
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Contact Tip
Kit
Cooling Attachment
Water Linc-Fill
K149
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K149
Water Linc-Fill
Cooling Attachment
Kit
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K148
With Water
Cooling
Attachment K148 & K149
LT-7 TRACTOR
C-6 ASSEMBLY C-6
K148 CONTACT NOzzLE
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Although designed primarily for the Innershield After the nozzle is positioned properly with respect to
process, this nozzle can be used with the with the LT-7 the travel direction, the connector tab for the electrode
for higher current and/or long stick-out submerged arc cables can be moved to any of four positions 90
applications. Water cooling can be added for longer tip degrees apart. To change the tab, remove the two 1/4-
life and the K149 Linc-Fill kit allows for longer stickout 20 hex head screws. Tap the connector tab to loosen it
applications.The two models recommended for use with from the tapered collar on the nozzle body. Turn the tab
the LT-7 are: to the desired position. Replace and tighten the 1/4-20
screws. See Figure C.3.
K148-A 3/32(2.4mm) and 1/8(3.2mm) wires
K148-B 5/32(4.0mm) and 3/16(4.8mm) wires The same contact tip, S13763, is used for 3/32 (2.4
mm) through 3/16 (4.8 mm) diameter electrodes.
S16388 is used for .062 (1.6 mm) and 5/64 (2.0 mm)
Current Ratings electrode.
A. Without Linc-Fill Attachment Straighten the start end of the coil for at least eight inch-
es, pass the end down through the appropriate wire
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Innershield Welding: straightener. Inch the wire through the wire feeder and
600 amps, 100% duty, no water cooling the nozzle.
1100 amps, 100% duty, with water cooling
Travel
Work
Connection
Weld Cable
Bolt (2)
1/4-20
Spring
Pivot Pressure
Nozzle Contact
Travel
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LT-7 TRACTOR
C-7 ASSEMBLY C-7
When welding with the small diameter electrodes, it will 4 a. Before installing the new tip, make sure the
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be necessary to change contact position more frequent- threads and the bottom surface of the nozzle are
ly since the amount of tip wear that can be tolerated is clean and bright. These surfaces are current
much less. carrying areas and must be clean.
The tang of the wire guide should never be allowed to b. Push on the nozzle body to relieve the pressure
touch the I.D. of the contact tip. If the groove is allowed and insert the new contact tip.
to wear until the tang touches the contact tip, welding
current will pass through the tang causing electrical 5. a. Check the locking ring threads making sure they
wear and overheating of both the tang and the contact are free or any foreign material. A small applica-
tip. See Figure C.4.a. tion of high temperature anti-seize compound on
these threads will insure a longer thread life of
To rotate the tip: the two mating parts.
1. Clip the end of the electrode and inch it up until it is b. Replace the locking ring and tighten securely.
free of the contact tip.
6. Check the contact tip to be certain it is tight in the
2. Loosen the locking nut about one-half turn and push nozzle body. If not, arcing will take place between
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against the nozzle body to relieve the pressure of the tip and the nozzle body which will damage the
the tang against the inside of the contact tip hole. nozzle body.
See Figure C.4. FIGURE C.4 - TIP REPLACEMENT
Head
Wire Feed
Locking Nut
Contact Tip
Spring
Pressure
Contact
3. Relieve the spring pressure of the steel tang in the Push to Contact Tip
hole of the contact tip. To do this, push the nozzle Relieve Locking Nut
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Tang Electrode
Tip
Contact
Contact
Tip
Tang Electrode
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11
F
G
14
13
12
C
H
contact tip. D
Tube
Cooling
Water
12. Replace the contact tip and its clamping nut (D) and
tighten securely.
Clamping Nut
LT-7 TRACTOR
C-9 ASSEMBLY C-9
Before attempting to reset the tractor for a specific type of joint, review the illustration below.
Left and Right throughout these instructions refers to left or right when facing the tractor as it comes toward you
as illustrated.
n
i r e ctio ng
D eldi
Left of W
Right
Butt Weld
Right Side
Weld
9.62
Butt Weld
Left Side
Butt Welds
Long Stickout
Left Side or
Mast
Main
Clamp Block
Adjuster
Cross Seam
Butt Welds
Short Stickout
Right Side or
Then arrange the head mounting and guidance system Short Stickout
as appropriate per the following instructions. Butt Welds
LT-7 TRACTOR
C-10 ASSEMBLY C-10
Cross Beam
Wheel
Steering
Arm
Clamp
b. To turn further right, loosen the left bolt and Cross Beam
tighten the right.
c. When the tracking is set, but sure both bolts Tracking Steering
are snug. Adjustment Wheel
To manually adjust the tracking while welding, simply
push the steering lever in the desired direction momen-
tarily and let it snap back into its preset position. An
extension arm shipped with each tractor can be
screwed into the steering arm when desired.
FIGURE C.10
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Pointer
Wing Screw
Clamp
LT-7 TRACTOR
C-11 ASSEMBLY C-11
FIGURE C.12
3. Channel Tracking - with a user provided straight max.
(25mm)
1
min.
(32mm)
1-1/4
Left
on
Track
Right
on
Track
max.
the front wheel toed slightly against the side
of the channel. (See Figure C.9). 1-1/4 Track Track
(32mm) on on
min. Left Right
FIGURE C.13
4. Bar Tracking - with a user provided straight bar 1/2" on Left
Track
on Right
Track
1 2 3 4
wide:
Track Track
on Left on Right
LT-7 TRACTOR
C-12 ASSEMBLY C-12
The K232 Fillet -Lap Guide Kit is recommended for horizontal fillet welding but with proper tracking or with the
Track Model LT-7 (See K395 or K400 information), these welds can be made by adjusting the Clamp Block,
Cross Seam Adjustment, Vertical Adjustment and Feed Head rotation as needed for proper alignment.
1. Whether to weld to the left side or right side of the 2. Mount the cross beam extending to the right of the
tractor. mast using the center and right mounting holes.
3. Mount the spacer pad and steer wheel housing to
2. What electrical stickout is required by the proce-
the left side of the clamp arm. See Figure C.14.
dures.
4. If welding to the left side of the tractor, mount the
3. Which steering method is best if not using a Track
clamp arm to the right end of the cross beam 3
Model. See Steering Methods.
(76.2 mm) from the end of the cross beam. If weld-
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Rearrange the head mounting and guidance system as ing to the right side, mount the clamp arm to the left
appropriate per the following instructions: end of the cross beam next to the mast .
Wheel
Steering
Spacer Pad
Clamp Arm
Mast
Cross Beam
Cross Beam
Mast
Clamp Arm
Spacer Pad
Steering
Wheel
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FRONT VIEW
LT-7 TRACTOR
C-13 ASSEMBLY C-13
HEAD MOUNTING
1. Mount the cross seam assembly on the mast near 4. Install either a K148 nozzle or a K231 nozzle . If
the top so it extends to the right. Move the clamp using Linc-Fill long stickout procedures, first install
block as close to the mast as possible. Turn the the K149 extension and the parts for the desired
cross seam adjuster hand wheel for full left position stickout on the K148 nozzle.
(i.e. completely closed).
5. Install the reel take-off tube to prevent contact with
the electrically hot electrode. Insert the nylon tube
2. Position the clamp block with the head mounting
into the take-off arm coupling. Thread the electrode
hole below the cross seam barrel. Install the head.
thru the tube and thru the wire straightener to the
Rotate the clamp block so the nozzle is 90 to the
drive rolls. Inch the electrode down thru the nozzle.
joint. Tighten the clamp. See Figure C.15.
6. While inching the electrode out of the nozzle, adjust
NOTE: The Clamp Block can be rotated above the
the straightener for properly straightened wire. Cut
Cross Seam adjuster for long stickout applica-
the wire off and set the electrode stickout as speci-
tions. (See Figure C.8).
fied in the procedure.
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Vertical
Screw Barrel Barrel
Pivot Plate
Locking Pivot Plate
Assembly
Cross Seam
Clamp Block
45
30
Block
Mast
Clamp
Adjuster
Adjust
Cross Seam
Vertical
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Cross Seam
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Adjust
Adjuster
Clamp
Mast
Block
30
45
Clamp Block
Cross Seam
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Assembly
LT-7 TRACTOR
C-14 ASSEMBLY C-14
The K232 FILLET-LAP GUIDE KIT is designed to provide precise positioning of the welding electrode into the fil-
let or lap joint. It consists of the following items and associated hardware:
Assembly
Wheel
Lap Guide
Assembly
Wheel
Fillet Guide
Block
Pivot
Fork
Yoke
Spring Assembly
Head Tension
Assembly
Adjustable Arm
Wheel Assembly
Rear Guide
Rear Guide
Wheel Assembly
Adjustable Arm
Assembly
Head Tension
Spring Assembly
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Yoke
Fork
Pivot
Block
Fillet Guide
Wheel
Assembly
Lap Guide
Wheel
Assembly
Wheel
(Fillet)
Rear Guide
Front Guide Wheel
Hook
Spring Finger
Head Tension
Adjustable Arm
Mounting Bolts
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Mounting Bolts
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Adjustable Arm
Head Tension
Spring Finger
Hook
Front Guide Wheel
Rear Guide
(Fillet)
Wheel
LT-7 TRACTOR
C-15 ASSEMBLY C-15
K232 INSTALLATION
1. Mount the adjustable arm to the head directly in front 4. Loosen the cross seam assembly lock bolt allowing
of the nozzle using the two bolts and washers pro- the pivot plate barrel to be free to rotate. Install the
vided. (Be sure the arm is square with its mount- head tension spring assembly shipped with the K232
ing.) Lock the slide in the full up position. kit. Place the loop on the spring over the cap screw
on the head and place a hole in the finger hook over
2. The front guide wheels are assembled to the fork at the cap screw at the bottom of the mast. Use the far-
the end of the adjustable arm. Be sure the flux hose thest hole from the end of the finger hook for right
loop extends to the left for left side fillets and to the side fillet and the closer hole for left side fillets.
right for right side fillets.
5. Lift the end of the nozzle so the pivot plate barrel
NOTE: If not using the Flux Cone Body of a K231 noz- rotates beyond the 40 position and tighten the lock
zle, use this loop to hold the flux hose. bolt. Then loosen the lock bolt just enough to permit
the tension spring to pull the head down to its prop-
3. Install the rear guide wheel into the socket behind er welding position.
the rear drive wheel with the guide wheel above the
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FIGURE C.17
arm. Use the socket by the left rear wheel for left Electrode
Fork
Arm
Adjustable
Block
Pivot
Electrode
Stickout
Loosen one and tighten the other until the electrode
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Set the tractor for left and right lap welding using the
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Adjustable Arm
Left Side Lap Weld
Bottom Plate
Plate
Guide Wheel
Top
Yoke
LT-7 TRACTOR
C-17 ASSEMBLY C-17
The K229 FLAT FILLET KIT is required for making flat fillet welds. It consists of the following items and associ-
ated hardware:
Front Support
Assembly
Rear Support
Reel Adapter
Bracket Assembly
Reel Adapter Front Support
Bracket Assembly
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Rear Support
Assembly
Assembly
Rear Support
Bracket
Reel Adapter
Reel Adapter
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Bracket
Rear Support
Assembly
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Front Support
Assembly
LT-7 TRACTOR
C-18 ASSEMBLY C-18
K229 INSTALLATION
FIGURE C.21
Before installing the K229 and depending upon the pro-
cedures and the weldment and clearances, decide:
45 7.5
16 30
Wheel
Steering
Threaded Hole
Cross Beam Spacer Pad
Clamp Arm
Mast
30 45
FRONT VIEW
(Contact Nozzle Removed)
Socket for
Rear Support
LT-7 TRACTOR
C-19 ASSEMBLY C-19
Adjust
Cross Seam
Mast
10
15
20
30
70
60
50
40
START
STOP
4. Mount the flux hopper to the flux hopper mounting
0
VOLTS
05
REVERSE
Mounting Assembly
01
DC LINCOLN WELD
LT-7 TRACTOR
SOLID STATE
20
DC
30
04
FORWARD
VOLTAGE DOWN
INCH
OF TRAVEL
DIRECTION
CURRENT UP
INCH
Reel and Control Box
MANUAL TRAVEL
OFF
0
AMPERES
01
AUTOMATIC TRAVEL
2
DC
4
6
8
Serial No.
Code No.
OFF
ON
POWER
CONTROL
AUTOMATIC TRAVEL
4
6
Code No.
Serial No.
ON
OFF
CONTROL
POWER
using the bracket on the vertical surface of the hop-
2
OFF DC
AMPERES
per. For 300 fillet, install the hopper to the left side of
MANUAL TRAVEL
DIRECTION INCH
CURRENT UP
OF TRAVEL
Mounting Assembly
FORWARD
INCH
VOLTAGE DOWN
40
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
LT-7 TRACTOR
C-20 ASSEMBLY C-20
The K395 TRACK MODEL LT-7, or standard K227 LT-7 with the K400 TRACK CONVERSION KIT installed, is
equipped for use on K396 TRACK SECTIONS. Either version permits complete use of the off-track versatility and
capability of the standard K227 LT-7.
The Track model provides precise track guidance and positive traction for single submerged arc or Tiny Twinarc
welding of butt or horizontal fillet / lap joints using standard LT-7 accessories or kits (refer to appropriate sections
of this manual.)
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The Track Model LT-7 provides the following features that are not included on the standard K227 LT-7 Tractor:
C. A longer nozzle weld cable, to extend the location of the head outside the right or left sides of the tractor.
D. A Travel Control Box nameplate with dual Travel speed scales.
The inside scale is calibrated for on-track Travel Speeds.
The outside scale is calibrated for off-track Travel Speeds
LT-7 TRACTOR
C-21 ASSEMBLY C-21
K395 CONFIGURATION
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The Track Model tractor can be configured for left or right 1. Mount the front rail wheel assembly, with nylon
side welding to over 7.5 (191 mm) outside the right or left bushings, to the steering assembly with the
sides of the track sections with forward or reverse travel grooved wheel on the right for right side welding,
directions. or on the left for left side welding.
2. Configure the converted front steering wheel
The K395 LT-7 is shipped set up for right side welding. If assembly so it is mounted on the right side of the
the left side welding is desired, or for left or right conver- clamp arm for the right side welding, or on the left
sion, proceed per the following instructions: for the left side welding. Check that the steering
assembly is set for straight travel.
NOTE: Right side of tractor welding is recommended 3. Mount the converted front wheel clamp arm
when using the K277 Tiny Twinarc Kit to assembly to the Mast Pad Extension Arm so the
provide optimum tractor stability. clamp is about 1/4 (6.4 mm) from the forward-fac-
ing Mast pad of the arm. The mast pad should be
A. Rear Wheel Configuration (See Figure C.26) to the right side for right side welding, or to the left
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and that there is only one flatwasher between tions, the flux hopper should be mounted on the
each wheel and its retaining snap ring side of the head closest to Track center.
Steering Assembly
Clamp Arm and
Front Wheel
Lift Adjuster
LT-7 Vertical Head
Assembly
Extension Arm
Mast Pad
Assembly
Gear Wheel
Combination
Wheel Assembly
(without nylon bushing)
Combination
Gear Wheel
Assembly
Mast Pad
Extension Arm
Assembly
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Combination Rail
Wheel Assembly
(with nylon bushing)
LEFT SIDE WELDING RIGHT SIDE WELDING
LT-7 TRACTOR
C-22 ASSEMBLY C-22
1. Remounting the vertical head lift adjuster to the LT- 5. M13469-5 Travel Box Nameplate
7 frame Mast pad. Remove the LT-7 Travel Control box speed con-
trol knob and the two phillips head screws
2. Unbolting the extension Mast pad from its securing the nameplate
crossarm.
6. S15184-1 - Control Box Extension Post
K400 LT-7 Track Conversion Kit Raises Control Box to face to the right.
NOTE: Older LT-7 Tractors, with a shorter head
The K400 kit allows field conversions of any code K227 cable, may not permit mounting the control box
standard LT-7 Tractor to a track model tractor, compara- facing the right side, but will permit forward fac-
ing controls.
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ble to the K395 LT-7, for use with the K396 Track
Sections.
7. M12700-2 - 24 (.6m) Weld Cable Assembly
Use the ON TRACK SETUP CONFIGURATION For applications requiring a further reach to the
instructions for proper installation to perform Right nozzle than permitted by the standard 18
Side or Left Side welding. (.45m) cable.
K400 Conversion Kit Parts (See Figure C.26) K396 Track Sections (Figure C.27)
1. S17632 - Gear Wheel Assemby The Track Sections are designed for use with a K395
Replaces a standard LT-7 rear wheel using the Track Model LT-7 Tractor, or with a K227 LT-7 Tractor
snap ring, washer and key removed with the with K400 LT-7 Track Conversion Kit installed.
standard wheel.
Each 70 (1.7 m) track section is made of 13.3 (338
2. S17634-1 - Rail Wheel Assembly (without nylon mm) wide 14 gauge sheet metal channel with .36 (9.1
bushings) mm) legs which sit on the floor. A rack and an L-shaped
Replaces a standard LT-7 rear wheel using the rail are fastened near opposite sides of the top surface.
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snap ring, washer and key removed with the The Track should be laid so all welding is performed on
standard wheel. the L-shaped rail side of the Track.
3. S17634-2 - Rail Wheel Assembly (with nylon The lightweight, 16.5 lbs (7.4 kg) track sections smooth-
bushings) ly slide together and provide self-aligned coupling and
Replaces a standard LT-7 front wheel using uncoupling without the use of any tools. This allows for
hardware removed from the standard wheel. Leap-frogging of track sections so that any desired
weld length can be accomplished quickly and precisely.
Rail
Rail
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Gear Rack
LT-7 TRACTOR
C-23 ASSEMBLY C-23
5*
4* 19
23
18
1*
1*
18
23
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4* 19
5*
6*
* Items 1, 4, 5 & 6 are for Flat Fillet welding and are only included in the K277-2
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LT-7 TRACTOR
C-24 ASSEMBLY C-24
LT-7 MODIFICATION FOR TWINARC WELDING
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1. Wire Straightener Modifications (Figure C.28) g. Remove the nut and lock washer from the bear-
ing mounting screw (Item 9).
a. Remove the standard single wire straightener
from the LT-7 tractor. h. Remove the 10-24 screw, lock washer, and nut
from the wire guide support (Item 2) which came
b. Remove and save roll pin (Item 6). with the kit, mount the support to the straightener
body using the hex nut and lock washer removed
c. Remove the screw bushing (Item 5). in Step (g).
d. Remove the slide screw assembly (Item 4) from i. Install the 10-24 screw, lock washer and nut (item
the single hole slide bushing (Item 8). 3) as shown.
e. Re-assemble the slide screw assembly (Item 4) NOTE: Earlier straightener bodies will not have a
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into the unit using the new double hole slide hole to receive the screw. Use a 13/64
bushing that came with the kit. (See drawing for (.203) diameter drill to provide a hole for the
proper orientation). screw].
f. Replace the screw bushing (Item 5); screw onto j. Remove the single hole ingoing guide tube from
threads with the small end first. Tighten it back the wire feed unit and install the two hole incom-
into the straightener frame until the roll pin holes ing guide tube which came with the kit. Snug up
in the bushing and the screw are lined up. the set screw into the indent of the guide tube.
Replace the roll pin (Item 6) removed in Step (b). Do not overtighten the set screw.
Apply a little grease to the screw threads.
k. Install the new straightener assembly to the wire
feed unit.
FIGURE C.28 - TWINARC WIRE STRAIGHTENER
7
6 3
5
4
8
1
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8
4
5
6 3
9
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LT-7 TRACTOR
C-25 ASSEMBLY C-25
2. Remove the entire head assembly from the clamp insulation which was removed in step (3).
block on the cross seam adjuster.
8. Remove the nozzle and hold down clamps and
3. Remove the head mounting pivot plate and its insu- screws.
lation by removing the two hex bolts (See Figure
C.29). 9. Remove the single wire outgoing guide tube by
loosening its set screw and replace it with the Tiny
4. Remove the idle roll arm assembly: Twinarc kit outgoing tube, being sure that the set
a. Remove arm pressure screw and spring. screw seats into the relief provided in the guide
b. Loosen arm pivot pin set screw and remove the tube.
pivot pin.
10. Mount the Tiny Twinarc nozzle using the socket
5. Remove the single wire drive rolls and replace head screws and lockwashers supplied in the kit.
them with the Tiny Twinarc drive rolls. Install the
three roll assembly with the narrow roll sandwiched 11. Do not remount the Feed Head assembly into the
cross seam adjuster clamp block before making
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LT-7 TRACTOR
C-26 ASSEMBLY C-26
10
15
20
30
70
60
50
40
START
STOP
0
VOLTS
05
01
DC LINCOLN WELD
LT-7 TRACTOR
SOLID STATE
REVERSE 20
30
DC
Mounting Assembly
04
FORWARD
VOLTAGE DOWN
INCH
OF TRAVEL
DIRECTION
CURRENT UP
INCH
Reel and Control Box
MANUAL TRAVEL
OFF
0
AMPERES
01
AUTOMATIC TRAVEL
2
DC
4
6
8
Serial No.
Code No.
OFF
ON
POWER
CONTROL
Code No. ON
CONTROL
6
4 Serial No. POWER
8
OFF DC
AMPERES
10
0
MANUAL TRAVEL
Mounting Assembly
FORWARD
INCH
VOLTAGE DOWN
30
REVERSE 20
DC
10
40
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
60
Store all parts that are removed from the tractor and that 5 70
START
are not being used for the current welding process for
future use.
Clamp
Hose Flux hose
Flux
Nozzle
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Nozzle
b. Install the stabilizer wheel attachment to the FIGURE C.32 - STABILIzER WHEEL
front mast mounting arm by clamping it onto
the mounting arm just behind the cross arm TOP VIEW
Mast
Head
Arm
Wheel
Steering
Attachment
Mounting
Direction
of Travel Wheel
Direction Stabilizer Front Mast
TOP VIEW
LT-7 TRACTOR
C-27 ASSEMBLY C-27
3. Horizontal Fillet Welds (Tiny Twinarc) FIGURE C.33 - CROSS SEAM ADJ.
below.
e. Left side fillet-laps require the following mod- FIGURE C.34 - SPRING ExTENDER
ifications to the single wire setup procedure:
L
the clamp block on the cross seam
adjuster.
R
2. Reverse the mounting of the cross seam
adjuster on the LT-7 mast so it extends Spring Extender
toward the left with the clamp block hole
above the cross seam adjuster barrel.
Then re-install the head assembly. See
Figure C.33. FIGURE C.35 - ExTENDED SUPPORT ARM
Wheel
Rear
Left
Roller Assembly
Support Arm
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1/2 to 1
Direction
Travel
1/2 to 1
lets.
Travel
f. For left horizontal fillets install the Support Arm Direction
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LT-7 TRACTOR
C-28 ASSEMBLY C-28
Bottom Plate
Plate
Guide Wheel
Top
Yoke
Adjustable Arm
b. The rear fillet support wheel attachment is not Left Side Lap Weld
required. For left laps the left rear wheel should
be approximately 8 (2.4 m) from the seam, and
for right laps the right rear wheel should be 5
(1.5 m) from the seam.
FIGURE C.38 - TINY TWINARC FLAT FILLET FINAL ASSEMBLY
.n
im
45
)m
45
16
m
09
(406
1(
5.
mm)
7
S16025 min.
Wheel Asby.
45 Front
S15279
Wheel
Support
Rear
M13396
Bracket
Extender
Wire Reel
L5629
Reel Asby.
Dual Wire
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Dual Wire
Reel Asby.
L5629
Wire Reel
Extender
Bracket
M13396
Rear
Support
Wheel
S15279
45 Front
Wheel Asby.
Return to Section TOC
.
Return to Master TOC
S16025 in
)m
m
m
6
40
7.
(
5
16
(1
9
45
0
45
m
m
)m
in
.
LT-7 TRACTOR
C-29 ASSEMBLY C-29
Cross Beam
Tapped Holes
extender bracket.)
Return to Master TOC
Tapped Holes
5. Remove the wire feeder, flux hopper assembly
and cross seam adjuster from the main mast. Cross Beam
Wire Reel
Extender
6. Remove the front wheel clamp arm and front Bracket 3/8-16x1.75
wheel assembly from the cross beam. Hex Screws
From Other Side
7. Reposition the main mast to the 45 degree posi-
tion (See K229 - Flat Fillet Head Mounting for
mast position).
LT-7 TRACTOR
C-30 ASSEMBLY C-30
Adjuster
Cross Seam
Block
Clamp
Mast
Main
17. Install the flux tube from the hopper to the flux
hose clamp as shown in Figure C.42. (Cut flux
hose length to suit.)
18. Install the rear support wheel (S15279) with the
roller down and the curved arm pointing to the FIGURE C.42 - FLUx HOPPER MOUNTING
rear of the tractor into the mounting socket which
is on the tractor frame just in front of the travel
motor.
Flux
Tip Adapter
Clamp
Flux Hose
Nozzle
Hose
Flux
20. Mount the control box into the socket which is on Flux Hose
the end of the curved arm of the reel extender. Clamp
Face of the control box should be to the left.
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Tip Adapter
21. Reconnect wire feed unit to the control box.
22. Install the travel motor extension cord and con-
nect it to the control box.
Store all parts that were removed from the tractor and
that are not being used for the current welding process
for future use.
LT-7 TRACTOR
C-31 ASSEMBLY C-31
1. Remove the complete wire feeder/flux hopper 5. Remove cross seam adjuster mast clamping screw
assembly from he vertical mast clamping screw and and replace it with the locking screw which is taped
slide the entire assembly up and off the mast. to the vertical lift mast. See Figure C.44.
2. Remove the vertical mast from the tractor frame by 6. Remount the complete wire feeder flux hopper
removing the two hex head bolts which fasten the assembly onto the new vertical lift mast. Lock at the
mast to the frame. desired height using the locking screw.
3. Remove the paper tape that is holding the two 7. Mount the hand adjusting knob, with the lock wash-
mounting screws in the vertical adjusting mast. er and nut and tighten securely.
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4. Mount the mast to the tractor frame and tighten the 8. Store the vertical mast and hardware that was
two mounting bolts securely. removed for future use.
Adjusting
Bolts
Mounting
Adjuster
Cross Seam
Screw
Locking
Screw
Locking
Lock Washer
Knob
Nut and
Adjusting
Adjuster
Head Lift
Vertical
Nut and
Knob
Lock Washer
Vertical
Head Lift
Adjuster
Locking
Screw Locking
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Screw
Cross Seam
Adjuster
FIGURE C.45
NOTE: Earlier units had a T Locking Screw instead of
a Wing Screw
Screw
Locking
T
T
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Mounting Locking
Bolts Screw
LT-7 TRACTOR
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-32
NOTES
LT-7 TRACTOR
C-32
Return to Master TOC D-1 TABLE OF CONTENTS - ELECTRICAL INSTALLATION D-1
LT-7 TRACTOR
D-2 ELECTRICAL INSTALLATION D-2
Cable(s)
Electrode
K1822-xx
Cable
Control
Cable
START
5 70
60
Shield
Travel Motor
10
50
STOP
05
LT-7 TRACTOR
15
40
Lower Coil
20
30
0
VOLTS
DC LINCOLN WELD
SOLID STATE
REVERSE
01
04
DC
20
30
VOLTAGE DOWN
FORWARD
INCH
OF TRAVEL
DIRECTION
CURRENT
INCH
UP
MANUAL TRAVEL
OFF
Cable
0
AMPERES
DC
01
AUTOMATIC TRAVEL
2
4
6
8
Code No.
POWER
ON
CONTROL
Cable
Code No. ON
CONTROL
6
AUTOMATIC TRAVEL
4 Serial No. OFF
POWER
8
OFF DC
AMPERES
10
0
MANUAL TRAVEL
DIRECTION INCH
CURRENT UP
OF TRAVEL
Lower Coil
FORWARD
Travel Motor
INCH
VOLTAGE DOWN
30
REVERSE 20
Shield
DC
10
40
20 LINCOLN WELD
Cable
DC
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
60
5 70
START
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Control
Cable
K1822-xx
Electrode
Cable(s)
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To avoid these situations, be sure to use ALL insulators Lead #67 to Greater than Before testing
provided. After installation, if these symptoms occur, Lead #21 1K ohms disconnect the
test resistances per Table D.1. If the test results are dif- welding cable(s)
ferent than the expected resistances consult the from the contact
Troubleshooting Guide. assembly
LT-7 TRACTOR
D-3 ELECTRICAL INSTALLATION D-3
1. The LT-7 requires 350 volt-amperes of 115 volt sin- NOTE: To connect Lincoln power sources not covered
gle phase 60 or 50 Hz power. Additional power is by the Connection Diagram Section, consult the
needed when a light (120 v/1a max.) is plugged into factory (1-888-935-3877) giving the Code
the outlet on the bottom of the control box. This AC Numbers for both the power source and LT-7.
power is available from the Lincoln power sources.
5. Thread the Control Cable (K1822-xx) and Electrode
2. The LT-7 is shipped, with the CV-VV switch inside Cable(s) up through the strain relief ring at the rear
the control box set to VV so it is ready to operate with of the tractor. Connect the polarized plug on the con-
a constant current power source. If the constant cur- trol cable to the mating receptacle below the control
rent process is desired, be sure that multi-process box. Connect the electrode cable(s) of approiate
power sources are set in the Constant Current mode size (see Table D.2) to the tab extending out of the
per the instructions in the power source operating top of the shunt box using the bolt and nut provided.
manual. See Figure D.1.
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NOTE: The term Constant Current (CC) was formerly 6. Connect the short length of electrode cable between
known as Variable Voltage (VV). To weld in the the front tab extending out of the tractor shunt box to
Constant Voltage (CV) Mode, see MODE the contact nozzle assembly. Route this cable under
SELECTION in Section E of this manual. the lower coil shield and around the right side of the
mast (looking at front of tractor) over the crossbeam.
4. Connect the input cable to the power source exactly See Figure D.1. Be sure the cable does not inter-
as specified on the appropriate connection diagram fere with the wire reel rotation and the connections
found in the LT-7 Operators Manual. Include all do not make contact with any part of the tractor
jumpers on the terminal strips as shown on the dia- frame.
grams, but do not add any jumpers not shown. If
using an SAF-600 or SA-800 motor-generator power 7. Connect a work lead of sufficient size and length
source, also include the K224 Solid-State Field (refer to Table D.2) between the Work stud on the
Control (obsolete) as shown in the diagram. power source and the workpiece. Be sure the con-
nection to the work makes a tight and clean metal-
to-metal contact.
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Combined Lengths of
Machine Duty Electrode & Work Cable
Size in Cycle
Amperes % 0-100 100-150 150-200 200-250
(0-30 m) (30-45m) (45-60m) (60-75m)
600 60 #3/0 #3/0 #4/0 (2) #3/0
600 80 (2) #1/0 (2) #1/0 (2) #2/0 (2) #3/0
600 100 (2) #1/0 (2) #1/0 (2) #2/0 (2) #3/0
#3/0
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LT-7 TRACTOR
D-4 ELECTRICAL INSTALLATION D-4
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3. Place the coil on the reel. Align cover plate FIGURE D.3
spokes to reel spokes and assemble. See
Figure D.3.
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LT-7 TRACTOR
D-5 ELECTRICAL INSTALLATION D-5
CAUTION
Always ensure the free end of the coil is
securely held while the tie wires are being
cut and until the wire is fully loaded in the
wire drive. Failure to do this may result in
a tangled coil.
-----------------------------------------------------
5. Cut and remove only the tie wire holding the free end
of the coil. Securely hook the free end of the elec-
trode wire through one of the holes in the cover
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9. Turn the power source ON. Feed the wire through the
wire straightener and ingoing guide to the drive rolls
and press the Inch Down button until the electrode
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CAUTION
DO NOT HOLD THE WELDING WIRE WITH BARE
HANDS WHILE INCHING DOWN
When Inching Down, a low voltage signal is
applied to the weld wire to enable the Auto Stop
Circuit. See Variable Voltage Circuit in section F.
NOTE: Always install the nylon take-off tube. If not
used while welding, the electrically hot elec-
trode may touch the control box or tractor
frameand cause the machine to stop welding.
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LT-7 TRACTOR
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-6
NOTES
LT-7 TRACTOR
D-6
Return to Master TOC E-1 TABLE OF CONTENTS - OPERATION SECTION E-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
LT-7 TRACTOR
E-2 OPERATION E-2
SAFETY PRECAUTIONS
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WARNING
ELECTRIC SHOCK CAN KILL
TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH
BEFORE WORKING ON THIS EQUIPMENT.
------------------------------------------------------------------------------------------------------------------------------
WARNING
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THE ELECTRODE REEL, DRIVE ROLLS, WHEELS, GUIDE WHEELS AND WIRE
STRAIGHTENER ROLLS TURN DURING WELDING OR INCHING.
KEEPS GLOVED HANDS AWAY FROM ROTATING PARTS THAT MAY CATCH THE
GLOVE.
DO NOT PLACE THE LT-7 TRACTOR ON INCLINED SURFACES WITH THE CLUTCH
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DISENGAGED.
------------------------------------------------------------------------------------------------------------------------------
LT-7 TRACTOR
E-3 OPERATION E-3
WARNING
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ELECTRODE POTENTIAL
MAINTAIN CLEARANCE BETWEEN PARTS AT ELECTRODE POTEN-
TIAL AND ALL OTHER TRACTOR COMPONENTS.
WELD WIRE
WIRE SPOOL
THE ENTIRE WIRE STRAIGHTENER
THE ENTIRE WIRE FEED HEAD
ELECTRODE CONNECTIONS
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------------------------------------------------------------------------------------------------------------------------------
Connections
Nozzle
Electrode
Contact
Reel
Wire
Head
Wire Feed
Straightener
Wire
START
70
60
STOP
105
50
40 LT-7 TRACTOR
15
20
30
0
VOLTS
DC
05
LINCOLN WELD
SOLID STATE
REVERSE
01
20
04
DC
30
VOLTAGE DOWN
FORWARD
INCH
OF TRAVEL
DIRECTION
CURRENT
INCH
UP
MANUAL TRAVEL
OFF
Weld Wire
0
AMPERES
DC
01
AUTOMATIC TRAVEL
2
4
6
8
Code No.
POWER
ON
CONTROL
Weld Wire
Code No. ON
CONTROL
6
AUTOMATIC TRAVEL
4 Serial No. OFF
POWER
2
OFF DC
AMPERES
10
0
MANUAL TRAVEL
DIRECTION INCH
CURRENT UP
OF TRAVEL
FORWARD
INCH
VOLTAGE DOWN
30
REVERSE 20
DC
10
40
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
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60
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5 70
START
Wire
Straightener
Wire Feed
Head
Wire
Reel
Contact
Electrode
Nozzle
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Connections
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LT-7 TRACTOR
E-4 THEORY OF OPERATION E-4
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CAUTION
Operate the LT-7 Tractor only on stable and dry surfaces.
--------------------------------------------------------------------------------------------------
LT-7 TRACTOR
E-5 THEORY OF OPERATION E-5
Meters Power
(CC is shown)
Control START
Nameplate (2)
Speed
70
60
Travel 105
50
STOP
40
05
LT-7 TRACTOR
15
20
30
0
VOLTS
DC LINCOLN WELD
SOLID STATE
01
20
04
DC
30
Box
OF TRAVEL
DIRECTION
CURRENT
INCH
UP
Travel
0
AMPERES
X100
01
OFF DC
AUTOMATIC TRAVEL
2
4
8
6
Serial No. OFF
POWER
Code No. ON
CONTROL
Switch
Meters THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO, MADE IN U.S.A. Power
Code No. ON
CONTROL
Switch
6 POWER
AUTOMATIC TRAVEL
4 Serial No. OFF
Travel
8
2
OFF DC
Control
AMPERES
10
0
X100
MANUAL TRAVEL
Box INCH
DIRECTION
CURRENT UP
OF TRAVEL
FORWARD
Travel VOLTAGE
INCH
Welding
DOWN
Direction REVERSE 20
30
Controls
DC
40
10
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
Travel 10
40 LT-7 TRACTOR
50
Speed 60
STOP
2. VOLTMETER - Shows actual voltage (both OCV and weld volts) after the START button is pressed.
4. INCH DOWN Button - Provides forward feed of wire through the feed head and Contact Nozzle.
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CAUTION
DO NOT HOLD THE WELDING WIRE WITH BARE HANDS WHILE INCHING DOWN
When Inching Down, a low voltage signal is applied to the weld wire to enable the Auto Stop Circuit.
7. Upper Welding Control - Controls the output of the power source. In CC Mode, it controls the Current and
in CV Mode it controls the Voltage.
8. Lower Welding Control - Controls the Wire feed Speed. In CC Mode it controls the Voltage and in CV Mode
it controls the Current.
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9. Nameplate - There are two (2) nameplates provided. One for CC (VV) Operation as shown in Figure E.2, and
one for CV operation (behind the VV nameplate)
NOTE: The CV nameplate labels the upper control as VOLTAGE, and the lower control as CURRENT. The
functions of the controls are as indicated above.
LT-7 TRACTOR
E-6 OPERATION E-6
GENERAL INFORMATION
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Once the LT-7 is configured properly for the type of weld to be done (i.e. fillet, butt, lap weld), the steering or track-
ing is properly set and the control and weld cables properly connected, the unit is ready to weld. Before welding,
the following decisions need to be made:
NOTE: Constant Current (CC) mode was formerly called Variable Voltage (VV).
The LT-7 is capable of welding in the Constant Current (CC) mode or Constant Voltage (CV) Mode. If the power
source being used is capable of either mode, the decision on which mode to use must be made before attempting
to weld. The following information explains the difference between the two modes.
The LT-7 Variable Voltage Board monitors the Arc voltage and varies the wire feed speed above and
below the set speed to compensate for voltage changes. It is normal for the voltage to fluctuate slightly.
The result is a constant arc length.
NOTE: The upper control of the LT-7 adjusts the power source output (current) and the lower control adjusts the
wire feed speed. In the CC mode, wire speed has the greatest impact on Voltage although both current
and voltage will change as the speed is varied due to the output characteristics of a CC power source.
The power source maintains a costant voltage output by allowing the current to fluctuate, compensating
for changes in the arc.
The LT-7 maintains a constant wire feed speed.
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LT-7 TRACTOR
E-7 OPERATION E-7
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* In CC operation it is typical for the Voltmeter to be less stable than the Ammeter
DC
AMPS
CURRENT
Total
VOLTAGE
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Electrical
Arc Length Stickout
(Volts)
DC
VOLTS
* In CV operation it is typical for the Ammeter to be less stable than the Voltmeter
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DC
AMPS
VOLTAGE
Total
CURRENT Electrical
Arc Length Stickout
(Volts)
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DC
VOLTS
LT-7 TRACTOR
E-8 OPERATION E-8
MODE SELECTION
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34
1
5
6
START
11
7
8
10
34
1
Serial No.
Code No.
6
7
11
10
8
9
9
VOLTAGE
CURRENT
OFF
ON
LT-7 TRACTOR
SOLID STATE
LINCOLN WELD
DC
DOWN
INCH
UP
INCH
POWER
CONTROL
4 8
NOTE: The term constant current (CC) was formerly
known as variable voltage (VV). The LT-7 3 9
3 9
2 10
DC
LINCOLN WELD
1 11 SOLID STATE
LT-7 TRACTOR
STOP
START
8
11
7
6
START
5
23
3
2
4
1
Serial No.
Code No.
6
7
11
10
8
9
CURRENT
VOLTAGE
OFF
ON
LT-7 TRACTOR
SOLID STATE
LINCOLN WELD
DC
DOWN
INCH
UP
INCH
POWER
CONTROL
Code No. ON
CONTROL
Serial No. POWER
1. Make certain that the Input power is turned OFF
OFF. 6
5 7
4 8
2. Remove the four screws (3 phillips and 1 slotted)
that hold the nameplates to the front panel of the 3 9
Control Box. 2 10
INCH
1 11
VOLTAGE UP
3. Put the Constant Voltage nameplate on top of the Use constant voltage D.C. power source
See Operaring Manual for using a
Variable Voltage nameplate and put both name- variable voltage power source
6
plates back on the front panel with the three 7 5 INCH
Phillips screws. 8 4
CURRENT DOWN
9 3
NOTE: The CV nameplate on newer machines has a 2
DC
10
black background with white lettering. LINCOLN WELD
11 1 SOLID STATE
LT-7 TRACTOR
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STOP
START
LT-7 TRACTOR
E-9 OPERATION E-9
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Ammeter
+
Voltmeter
EGATLOV ELBAIRAV
DRAOB
VC
L
VV
H
start the weld with the electrode NOT touching
VV
the work.
H
VARIABLE VOLTAGE
5. Close the front panel, being careful not to pinch
any leads, and replace the slotted head screw.
CV
L
BOARD
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POLARITY SELECTION
Ammeter
the output studs of the power source
+
3. Remove the slotted head screw at the upper left
corner of the nameplate and drop the front panel
down.
LT-7 TRACTOR
E-10 OPERATION E-10
MAKING A WELD
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Once the LT-7 is configured properly for the type of weld to be done (i.e. fillet, butt, lap weld), the steering or track-
ing is properly set, the control and weld cables properly connected, and the proper Weld Mode and Polarity are
selected the unit is ready to weld.
1. Load the wire reel and flux hopper. All re-used flux must be screened 100% through a screen with 3/32
(2.4 mm) maximum openings (8 mesh).
2. Place the tractor on the joint. Adjust the head for the proper electrial stickout (E.S.O.).
3. Set the travel switch to Automatic Travel , set the Direction of Travel to Forward and engage the Clutch
Mechanism.
4. Set the travel speed, welding current and arc voltage as required by the procedures.
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If the Current andVoltage settings have not been previously established, set the Current Control to about
#4 and the Voltage Control to about #7.
5. Feed the wire through the nylon conduit and into the wire straightener.
6. Use the INCHDOWN button to feed the wire through the drive rolls and the contact nozzle.
CAUTION
DO NOT HOLD THE WELDING WIRE WITH BARE HANDS WHILE INCHING DOWN
When Inching Down, a low voltage signal is applied to the weld wire to enable the Auto Stop Circuit
NOTE: If the Variable Voltage Board jumper is required to be on the L pin, the wire will not stop when it
touches the work. It will be necessary to use hot starting.
b. For hot starting, feed the electrode to approximately 1/8 above the work piece. Cut electrode to a
sharp point before each weld.
8. Open the manual flux valve.
9. Press the START button to start the wire feed and tractor drive motors.
10. While welding, adjust the LT-7 Voltage and Current settings for the proper weld procedure. Also adjust
the flux flow valve to deposit just enough flux to prevent excessive visible flash through.
11. At the end of the weld, press the STOP button to stop the wire feed and tractor drive motors. For a fixed
time delay (~ .3 sec.) the welder output will remain on to prevent the electrode from sticking in the puddle
12. Turn the flux valve off.
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LT-7 TRACTOR
E-11 OPERATION E-11
FIGURE E.8
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Travel Control
(both sides)
Clutch Handle
Drive Wheel
Control
Travel Speed
Switch
START
70
60
Direction
105
50
STOP
40
05
LT-7 TRACTOR
15
20
30
0
VOLTS
DC LINCOLN WELD
SOLID STATE
04
DC
REVERSE
01
20
30
Travel Switch
VOLTAGE DOWN
FORWARD
INCH
OF TRAVEL
DIRECTION
CURRENT
INCH
UP
MANUAL TRAVEL
Box
OFF
0
AMPERES
DC
01
AUTOMATIC TRAVEL
2
4
6
8
Serial No. OFF
Travel Control
Code No.
POWER
ON
CONTROL
Box
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO, MADE IN U.S.A.
Code No. ON
CONTROL
6
AUTOMATIC TRAVEL
4 Serial No. OFF
POWER
8
OFF DC
AMPERES
10
0
Travel Switch
MANUAL TRAVEL
DIRECTION INCH
CURRENT UP
OF TRAVEL
FORWARD
INCH
VOLTAGE DOWN
Direction
30
REVERSE 20
DC
10
40
20 DC LINCOLN WELD
15 30
Switch
VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
60
5 70
START
Travel Speed
Control
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Front
Travel Motor Guidance
and Gear Box Assembly
Drive Wheel
Clutch Handle
(both sides)
FIGURE E.9
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Meters Power
CC Operation
START is for
70
60
STOP
Nameplate Shown
105
50
40 LT-7 TRACTOR
05
15 30
0
20 DC LINCOLN WELD
DC
Controls
01
04
REVERSE 20
30
VOLTAGE DOWN
INCH
Welding
FORWARD
OF TRAVEL
DIRECTION
CURRENT UP
INCH
MANUAL TRAVEL
X100
0
AMPERES
01
OFF DC
AUTOMATIC TRAVEL
2
Code No. ON
CONTROL
Switch
6 POWER
AUTOMATIC TRAVEL
4 Serial No. OFF
8
2
OFF DC
AMPERES
10
0
X100
MANUAL TRAVEL
DIRECTION INCH
CURRENT UP
OF TRAVEL
FORWARD
VOLTAGE
INCH
DOWN Welding
Controls
30
REVERSE 20
DC
40
10
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
Nameplate Shown
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60
5 70
START is for
CC Operation
LT-7 TRACTOR
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-12
NOTES
LT-7 TRACTOR
E-12
Return to Master TOC F-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION F-1
TRAVEL
DIRECTION
SWITCH
TRAVEL
SPEED
CONTROL
A 115VAC OFF
B AUTO
INCH UP
C
1CR SWITCH
POWER SOURCE 2CR
CONTACT RELAY TRAVEL
31
#2 RELAY 115VAC
#4
115VAC GLP WELD CURRENT
WIRE REED SENSING REED
FROM CIRCUIT
R1 DRIVE SWITCH 4CR SWITCH 3CR
WELDING BREAKER
115VAC CONTROL MOTOR
POWER
SOURCE BOARD
CV VV
115VAC
L
H INCH
DOWN
INCH
SPEED
SWITCH
21 67
VOLTAGE
SENSING
LEADS
{ ELECTRODE
WORK
ARC
VOLTAGE
METER
WIRE
SPEED
CONTROL
115VAC 115VAC
LT-7 TRACTOR
F-2 THEORY OF OPERATION F-2
TRAVEL
DIRECTION
SWITCH
TRAVEL
SPEED
CONTROL
#4
115VAC GLP WELD CURRENT
WIRE REED SENSING REED
FROM CIRCUIT
R1 DRIVE SWITCH 4CR SWITCH 3CR
WELDING BREAKER
115VAC CONTROL MOTOR
POWER
SOURCE BOARD
115VAC
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32 24VDC
VOLTAGE
SENSING
LEADS
{ ELECTRODE
WORK
ARC
VOLTAGE
METER
WIRE
SPEED
CONTROL
115VAC 115VAC
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The LT-7 tractor is a compact, lightweight, DC, single The LT-7 is powered by 120VAC which is usually sup-
arc tractor. It is capable of operating with 3/32 plied from the welding power source. This voltage is
through 3/16 electrode with a current carrying capaci- applied to the control box circuitry through the ON/OFF
ty of 1000 amps. The LT-7 has a travel range from 6 power switch and a 3 Amp circuit breaker. The input
to 70 inches per minute. power is also applied to the the Variable Voltage Board
and, through resistor R1, to the Control Board.
LT-7 TRACTOR
F-3 THEORY OF OPERATION F-3
TRAVEL
115VAC
{
115VAC
CONTROL
LEADS WORK METER SPEED
SENSING VOLTAGE WIRE
VOLTAGE ELECTRODE ARC
21 67
SWITCH
DOWN
115VAC
L
H INCH
SPEED
INCH
CV VV
BOARD SWITCH
115VAC VARIABLE VOLTAGE STOP
BOARD
SWITCH LOGIC
START
GND
ARC VOLTAGE SENSING SIGNALS
32 24VDC
115VAC
LOGIC CONTROL SIGNALS
SOURCE BOARD
POWER
WELDING BREAKER
115VAC CONTROL MOTOR
R1
FROM CIRCUIT
DRIVE SWITCH 4CR SWITCH 3CR
115VAC
WIRE REED SENSING REED
#4
GLP WELD CURRENT
#2 RELAY 115VAC
31 CONTACT RELAY TRAVEL
POWER SOURCE 2CR
1CR SWITCH
C
INCH UP
B AUTO
A 115VAC OFF
SWITCH
CONTROL CONTROL MANUAL
OUTPUT TRAVEL
MOTOR
TRAVEL BOARD TRAVEL
CONTROL
SPEED
TRAVEL
SWITCH
DIRECTION
TRAVEL
DIRECTION
SWITCH
TRAVEL
SPEED
CONTROL
#4
115VAC GLP WELD CURRENT
WIRE REED SENSING REED
FROM CIRCUIT
R1 DRIVE SWITCH 4CR SWITCH 3CR
WELDING BREAKER
115VAC CONTROL MOTOR
POWER
SOURCE BOARD
32 24VDC
VOLTAGE
SENSING
LEADS
{ ELECTRODE
WORK
ARC
VOLTAGE
METER
WIRE
SPEED
CONTROL
115VAC 115VAC
CONTROL AND LOGIC CIRCUITS The START switch signals the logic board to start the
wire feed, activate the power source contact relay
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switches or potentiometers, the logic board sends the INCH speed trimmer.
appropriate signal to the control board. The Control
The STOP switch signals the Locic Board to shut
board then drives the wire feed motor at the correct
down the wire feed, the travel and after a short time
speed and in the proper direction.
delay (~ .3 sec.), the power source output.
LT-7 TRACTOR
F-4 THEORY OF OPERATION F-4
TRAVEL
DIRECTION
SWITCH
TRAVEL
SPEED
CONTROL
#4
115VAC GLP WELD CURRENT
WIRE REED SENSING REED
FROM CIRCUIT
R1 DRIVE SWITCH 4CR SWITCH 3CR
WELDING BREAKER
115VAC CONTROL MOTOR
POWER
SOURCE BOARD
32 24VDC
VOLTAGE
SENSING
LEADS
{ ELECTRODE
WORK
ARC
VOLTAGE
METER
WIRE
SPEED
CONTROL
115VAC 115VAC
TRAVEL CIRCUIT
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The Travel Circuit receives 120vac power directly from the Older LT-7 units had a shunt wound motor which required
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ON/Off siwtch. One leg of the power is applied through the a 120vdc power supply to the motor field circuit. This sup-
.8 Amp circuit breaker in the Travel Control Box. The other ply was also located on the Travel Control Board and the
side is applied by way of the Travel Control Switch, either polarity was switched by the Direction Switch.
directly for Manual travel or through the 2CR relay con-
tact for Automatic travel when the START button is acti- That motor was replaced by the current permanent mag-
vated. net motor. In the newer units, the direction is changed by
reversing the polarity of the voltage to the armature.
The Travel Control Board contains an SCR circuit to pro-
vide armature voltage of about 5 to 90 vdc to the Travel Wiring diagrams for both versions of the travel circuit are
Motor.(See SCR Operation) in this section. The speed is in the Section J of this manual.
dertermined by the Travel Speed Control. The nameplate
on the Travel Control Box is calibrated in inches/min.
LT-7 TRACTOR
F-5 THEORY OF OPERATION F-5
TRAVEL
DIRECTION
SWITCH
TRAVEL
SPEED
CONTROL
#4
115VAC GLP WELD CURRENT
WIRE REED SENSING REED
FROM CIRCUIT
R1 DRIVE SWITCH 4CR SWITCH 3CR
WELDING BREAKER
115VAC CONTROL MOTOR
POWER
SOURCE BOARD
START
SWITCH LOGIC
BOARD
115VAC VARIABLE VOLTAGE STOP
BOARD SWITCH
CV VV
115VAC
L
H INCH
DOWN
INCH
SPEED
SWITCH
21 67
VOLTAGE
SENSING
LEADS
{ ELECTRODE
WORK
ARC
VOLTAGE
METER
WIRE
SPEED
CONTROL
115VAC 115VAC
LT-7 TRACTOR
F-6 THEORY OF OPERATION F-6
INPUT
GATE
IS DECREASED.
THE SCR OUTPUT
ANODE LATER IN THE CYCLE
PULSE IS APPLIED
NOTE: AS THE GATE
CATHODE
INPUTOUTPUT
CATHODE
OUTPUT
NOTE: AS THE GATE
PULSE IS APPLIED
ANODE LATER IN THE CYCLE
THE SCR OUTPUT
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IS DECREASED.
GATE
SCR OPERATION
The wire speed and the travel speed of the LT-7 is The firing signal consists of a short burst of current
controlled by silicon-controlled rectifier (SCR) circuitry, into the gate that is positive with respect to the
so a basic understanding of how an SCR functions is cathode. Since there is a standard PN junction
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important.
be slightly greater than 0.6 VDC. Once the SCR has
fired, it is not necessary to continue the flow of the gate
An SCR is a three-terminal semiconductor device used
current. As long as the current continues to flow from
to control currents to a load. An SCR acts very much
anode to cathode, the SCR will remain on. When the
like a switch. When a gate signal is applied to the SCR,
anode to cathode current drops below a minimum
it is turned on and there is current flow from anode to
value, called the holding current, the SCR will shut off.
cathode. In the on state, the SCR acts like a closed
This normally occurs as the AC supply voltage passes
switch. When the SCR is turned off, there is no current
through zero into the negative portion of the sine wave.
flow. As the name suggests, the SCR is a rectifier, so
it passes current only during positive half cycles of the If the SCR is turned on early in the positive half cycle,
AC supply. The positive half cycle is the portion of the the conduction time is longer, resulting in greater SCR
sine wave in which the anode of the SCR is more output. If the gate firing time is later in the cycle, the
positive than the cathode. conduction time is less, resulting in lower SCR output.
See Figure F.5.
When an AC supply is applied to the SCR, the device
spends a certain portion of the AC cycle time in the on Full wave rectification requires two SCRs - one for
state and the remainder of the time in the off state.
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LT-7 TRACTOR
Return to Master TOC G-1 TABLE OF CONTENTS - MAINTENANCE SECTION G-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
LT-7 TRACTOR
G-2 MAINTENANCE G-2
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Routine Maintenance
CAUTION
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If for any reason a user does not understand the test procedures or is unable to per-
form the tests/repairs safely, contact a local authorized Lincoln Electric Field Service
Facility for technical assistance.
Observe all safety guidelines detailed in the beginning and throughout this manual.
------------------------------------------------------------------------------------------------------------------------------
WARNING
ELECTRIC SHOCK can kill.
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Turn the input power off at the fuse box before working on equipment.
Do not touch electrically hot parts.
-------------------------------------------------------------------------------------------------
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LT-7 TRACTOR
G-3 MAINTENANCE G-3
plate
Inspection
2. Coat the teeth of the motor pinion gear and the heli-
cal gears with graphite grease. The grease can be
scooped from the inside of the gearbox and re-
deposited on the gears. Brush
Holder
3. Replace the Inspection Plate.
Wire Guide
Ingoing
Pin
Roll
Bushing
Slide
Slide
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LT-7 TRACTOR
G-4 MAINTENANCE G-4
The nozzle contact tip must be replaced when it is no NOTE: The LT-7 (earlier models only) is shipped with
longer provides accurate wire location or good electrical spare fuses taped to the left side of the control
contract. See the appropriate contact nozzle informa- box inside. On the later models all fuses on the
tion (K231 or K148) in Section C of this manual for fur- control board have been replaced with PTCs
ther information. (self resetting fuses). These devices will shut-
down the circuit if overloaded, but will automat-
Wire Reel Mounting 50 and 60 Pound ically reset after the overload condition has
Coils been removed. Should one or these devices
trip, turn off the power to the unit and remove
To prolong the life of the reel shaft, periodically coat it the source of the overload (See the
with a thin layer of grease. Troubleshooting Guide for possible reasons
for fuse blowing). Allow a few minutes for the
device to cool down before restoring power.
Control Box
For proper clutch operation, occasionally lubricate the 1. Turn the LT-7 Power Switch OFF.
gear and sliding surfaces of the rear axle with a dry
lubricant, such as moly disulfide powder. 2. Clear the fault by eliminating the source of electrode
to frame contact.
Circuit Protection 3. Turn the LT-7 Power Switch back on.
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The AC input line is protected by the circuit breaker 4. If the fault was cleared succesfully, the unit is ready
mounted between the LT-7 meters. It protects LT-7 from for operation.
shorts and from overloads, usually caused by excessive
wire drag or other wire feeding problems. To reset the Nuisance GLP Circuit tripping when there is no actual
circuit breaker, push the red button. If it opens again, ground fault can be caused by the following conditions:
determine the cause of the overload. The LT-7 light out-
let is not protected by the circuit breaker. If the work piece is common with earth ground and
the LT-7 frame is common with the work because of
In earlier models, if a short occurs in the field circuit of uninsulated guide rollers, some current will be
either the wire feed or travel motors, or if there is a shared by the safety ground lead. If this current
defect on the P.C. board, a 1/2 amp slow-blow type fuse becomes excessive due to poor connections or
will blow. This field circuit fuse is mounted on the con- undersized work cables, the GLP circuit may acti-
trol P.C. board inside the respective weld or travel con- vate. Repair the connections or add parallel work
trol box. Before replacing the fuse, check the motor field cables.
for a shorted condition.
Coiled up control cables bundled with weld cables
In earlier models, if a P.C board component fails and
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LT-7 TRACTOR
Return to Master TOC H-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR H-1
LT-7 TRACTOR
H-2 TROUBLESHOOTING AND REPAIR H-2
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
This Troubleshooting Guide is provided to Step 3. RECOMMENDED
help you locate and repair possible machine COURSE OF ACTION
malfunctions. Simply follow the three-step The last column labeled Recommended
procedure listed below. Course of Action lists the most likely com-
ponents that may have failed in your
Step 1. LOCATE PROBLEM(SYMPTOM). machine. It also specifies the appropriate
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Look under the column labeled PROBLEM test procedure to verify that the subject com-
(SYMPTOMS). This column describes pos- ponent is either good or bad. If there are a
sible symptoms that the machine may exhib- number of possible components, check the
it. Find the listing that best describes the components in the order listed to eliminate
symptom that the machine is exhibiting. one possibility at a time until you locate the
Symptoms are grouped into the following cause of your problem.
categories: output problems, function prob-
lems, wire feeding problems, and welding All of the referenced test procedures
problems. referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Step 2. PERFORM EXTERNAL TESTS. Refer to the Troubleshooting and Repair
The second column labeled POSSIBLE Table of Contents to locate each specific
AREAS OF MISADJUSTMENT(S) lists the Test Procedure. All of the specified test
obvious external possibilities that may con- points, components, terminal strips, etc. can
tribute to the machine symptom. Perform be found on the referenced electrical wiring
these tests/checks in the order listed. In diagrams and schematics. Refer to the
general, these tests can be conducted with- Electrical Diagrams Section Table of
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out removing the case wrap-around cover. Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
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LT-7 TRACTOR
H-3 TROUBLESHOOTING AND REPAIR H-3
PC board can be damaged by static electricity. b. If the original problem is recreated by the
- Remove your bodys static substitution of the original board, then the PC
charge before opening the static- board was the problem. Reinstall the
shielding bag. Wear an anti-static replacement PC board and test the machine.
wrist strap. For safety, use a 1 6. Always indicate that this procedure was
Meg ohm resistive cord connected followed when warranty reports are to be
ATTENTION to a grounded part of the submitted.
Static-Sensitive equipment frame.
NOTE: Following this procedure and writing on the
Devices - If you dont have a wrist strap, warranty report, INSTALLED AND SWITCHED PC
Handle only at touch an un-painted, grounded,
BOARDS TO VERIFY PROBLEM, will help avoid
Static-Safe part of the equipment frame. Keep denial of legitimate PC board warranty claims.
Workstations touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
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LT-7 TRACTOR
H-4 TROUBLESHOOTING AND REPAIR H-4
OUTPUT PROBLEMS
Wire feeds whenever Power 1. Check the Start Switch(S5). 1. If LED 1B on the Control Board is
Switch (S1) is turned ON. Make certain it is not stuck OFF the Control Board may be
closed. faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-5 TROUBLESHOOTING AND REPAIR H-5
OUTPUT PROBLEMS
LT-7 is dead - No wire feed with 1. Make sure the Power Switch (S1) 1. Check LEDs 1C and 1D on the
INCH buttons and no travel, wire is on and functioning properly. Control Board. If both LEDs are
feed or welder output with START ON at the same time replace
button. 2. Check the circuit breaker located the Control Board.
on the front cover. If tripped -
reset. If circuit breaker repeated- 2. Press the inch up switch. LEDs
ly trips during operation consult 1D and 1E, on the Control
the appropriate PROBLEMS Board should be ON. If either
(SYMPTOMS) portion of this one is OFF the Control Board
guide. may be faulty.
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3. Open the front cover and inner 3. If LED 1D and 1E are ON and
panel to check if any of the LEDs the wire drive motor does not
on the printed circuit boards are turn check the continuity of
lit. See the PC Board Status leads #539, #541, #626 and
Light Table. If none of the LEDs #627 from the Control Board to
are lit, the control circiut is NOT the wire drive motor.
receiving any power. Check the
2/10 amp fuse on the Control 4. Perform the Wire Drive Motor
Board. Also make sure that Test.
115VAC is present on leads #631
and #532. Check R1. See the
Wiring Diagram.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-6 TROUBLESHOOTING AND REPAIR H-6
OUTPUT PROBLEMS
The wire will not feed and the circuit 1. Reset the circuit breaker and 1. If when at idle LED 1D is ON and
breaker trips when the Inch or Start observe LEDs 1C and 1D on the LED 1C is OFF then perform the
switches are pressed. Control Board with the unit at idle Wire Drive Motor Test.
(not attempting to feed wire).
LED 1C should be OFF and LED
1D should be ON. If both LEDs
are OFF remove power and
check the 1/2 amp field fuse
(F101) if present. (On newer
boards the field fuse was
replaced with a PTC self reset-
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ting fuse).
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-7 TROUBLESHOOTING AND REPAIR H-7
OUTPUT PROBLEMS
The wire will not feed when the 1. If LED 2M on the Logic Board is 1. If LED 2B is ON when the start
Start Switch is pressed. There is no ON the ground lead protector has switch is pressed and LED 2M
voltage indicated on the LT-7 volt- tripped. Make sure the LT-7 head does NOT turn ON then the
meter. The wire does inch up and or electrode are NOT contacting Logic Board may be faulty.
down properly. the LT-7 frame or control box.
The wire will NOT inch down but 1. Press the inch down switch and 1. If LED 1B does NOT turn ON,
inches up properly. When the Start observe LED 1B on the Control when the Inch Down switch is
Switch is pressed the wire does not Board. If LED 1B is ON and the pressed, measure the DC volt-
feed. motor does not activate the age from lead #586 to lead
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-8 TROUBLESHOOTING AND REPAIR H-8
OUTPUT PROBLEMS
The wire will NOT inch down but 1. While pressing the Inch Down 1. Disconnect lead #21 from the
does inch up properly. When the Switch observe LED 2J. It welder terminal strip. Turn on
Start Switch is pressed the wire should be ON. If not the inch input power and while pressing
feeds down properly. down switch (S4) or associated the Inch Down Switch observe
wires may be faulty. See the LED 3A. If LED 3A does NOT
Wiring Diagram. light the Variable Voltage Board
may be faulty. Replace board
2. Move the VV Board jumper to and reconnect lead #21.
the L terminal and press the
Inch Down switch. If LED 2J If LED 3A turns ON with lead
comes ON but the wire still does #21 disconnected, the resis-
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not feed, the Logic Board may be tance across leads #21 and
faulty. #67 is too low. The resistance
must be above 500 ohms. See
the Variable Voltage Board
discussion in Section F. The
low resistance could also be
caused by the following:
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-9 TROUBLESHOOTING AND REPAIR H-9
OUTPUT PROBLEMS
The wire will not inch down. The 1. Check the connections between 1. Check lead #21 at the VV Board
wire inches up properly. When the the power source and LT-7 for for continuity (zero ohms) to
Start Switch is pressed the wire loose or incorrect connections. work.
feeds up instead of down.
2. Check the leads connected to 2. Check lead #67 at the VV Board
the Variable Voltage Board for for continuity (zero ohms) to
loose or faulty connections. electrode.
faulty.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-10 TROUBLESHOOTING AND REPAIR H-10
OUTPUT PROBLEMS
When inching down, the wire does 1. The jumper on the Variable 1. Check lead #21 for continuity
not stop feeding when it touches Voltage Board must be connect- (zero ohms) to work.
the work piece. ed to the H pin for the Auto-
Stop circuit to function. See the 2. Check lead #67 for continuity
Variable Voltage Board discus- (zero ohms) to electrode.
sion in Section F of this manual.
3. The Logic Board may be faulty.
The wire will not inch up. The wire 1. With LT-7 at idle (not feeding 1. If LED 1A does light but the
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inches down properly. wire) observe LED 1D on the wire does not feed the Control
Control Board. The light should Board may be faulty. Replace.
be ON. If LED 1D is OFF the
Control Board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-11 TROUBLESHOOTING AND REPAIR H-11
OUTPUT PROBLEMS
The wire feeds up with either inch 1. While pressing the Inch Down 1. Check the wiring to the Inch
switch. Switch observe LED 2E on the Down Switch. See the Wiring
Logic Board. If LED 2E does Diagram.
NOT light the Logic Board may
be faulty. 2. Check the wiring between the
Logic Board and the Control
2. If LED 2E does light the Control Board. See the Wiring
Board may be faulty. Diagram.
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The wire feeds at full speed during 1. Remove electrode from drive 1. Check leads #634, #641 and
the weld mode (only). rolls and place a jumper wire #642 between wire feed speed
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from lead #528 to lead #539 on control (R3) and Logic Board.
the reed switch(CR3) in the shunt
box. Press the Start Switch and 2. Check R3 rheostat for correct
observe LEDs 2L and 2D on the resistance (5000 ohms) and
Logic Board. Both lights should proper function.
be ON. If light 2D is ON and light
2L is OFF, the Logic Board may
be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-12 TROUBLESHOOTING AND REPAIR H-12
OUTPUT PROBLEMS
The wire feeds at full speed in both 1. With the LT-7 at idle (not feeding 1. Perform the Wire Drive Motor
inch and weld modes wire) observe light 2F on the Test. The Field circuit may be
Logic Board. If light 2F is ON the open.
Control Board may be faulty.
The wire has limited or erratic 1. Put the CV-VV switch is in the CV 1. Perform the Wire Drive Motor
speed control in one or more mode. If the motor runs properly, Test.
modes. the Variable Voltage Board may
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-13 TROUBLESHOOTING AND REPAIR H-13
OUTPUT PROBLEMS
The wire feeds up instead of down 1. Check for proper connection of 1. Check lead #21 for continuity
when the Start Switch is pressed. electrode leads and control cable (zero ohms) to work.
There is no voltage reading on LT-7 leads from power source to LT-7.
voltmeter. The wire inches up and 2. Check lead #67 for continuity
down properly. 2. On Lincoln power sources put a (zero ohms) to electrode.
jumper from #2 to #4 on the ter-
minal strip. This activates the 3. Check leads #2 and #4 for
output from the power source. loose or faulty connections
between relay CR1 and the
Test for voltage at the output control cable receptacle.
terminals of the power source.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-14 TROUBLESHOOTING AND REPAIR H-14
OUTPUT PROBLEMS
No control of power source output 1. Check control cable leads for 1. Check the continuity of leads A,
from LT-7 tractor. Power source proper connection to power B, and C in the control cable.
does have output. source.
NOTE: Older cabes were labled
NOTE: The upper control always 2. Make sure the Lincoln power 75,76 & 77 instead of A,B,C
adjusts the power source source is in the remote control
output. mode. 2. Check the resistance and oper-
ation of the voltage control
rheostat (R2). Normal resis-
tance is 10,000 ohms.
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The circuit breaker trips while the 1. Disconnect the wire feed and 1. If the problem is not in a motor
LT-7 is at idle (not feeding wire). travel motors one at a time. If the or a printed circuit board then
breaker holds, check that motor. check the wiring harness for
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-15 TROUBLESHOOTING AND REPAIR H-15
OUTPUT PROBLEMS
The power source output contactor 1. With the LT-7 at idle (not feeding 1. Turn the power source OFF
does NOT drop out. The power wire) observe LED 2K on the and disconnect the LT-7
source output terminals are always Logic Board. It should be OFF. If Control Cable (if using a 14
electrically hot. LED 2K is ON, the Logic Board pin MS type Connrector) or
may be faulty. disconnect lead #4 from the
Terminal Strip.
2. If LED 2K is OFF (with the LT-7 at
idle) locate and remove the Turn the power source ON.
power and disconnect lead #4 If the output is still hot with
from the 1CR relay. the control cable or lead #4
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The welding and travel do not stop 1. Press and hold the Stop Switch 1. If light 2C is ON the Logic
when the stop switch is pressed. while observing LED 2C. Board may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-16 TROUBLESHOOTING AND REPAIR H-16
OUTPUT PROBLEMS
The travel motor does not run in 1. Make sure the circuit breaker is 1. Check the DC armature voltage
either the MANUAL or AUTO- NOT tripped. being applied to the travel
MATIC position. motor. Leads #595 to #594.
2. Set the travel switch in manual Normal is 0 to 85VDC. depend-
mode. Check the voltage at the ing upon the travel speed set-
travel board #531 to #632 at the ting.
circuit breaker. Normal is 105 to
130VAC. If the correct voltage is NOTE: In older units the travel
NOT present check the circuit motor may be a shunt
breaker, the R5 resistor, the trav- wound motor with sepa-
el switch and the associated rately powered field coils.
Return to Section TOC
Return to Master TOC
Motor Test.
Return to Section TOC
Return to Master TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-17 TROUBLESHOOTING AND REPAIR H-17
OUTPUT PROBLEMS
The travel motor will not run with 1. Check LED 2H on Logic Board. 1. The travel control switch (S2) or
travel switch set on automatic. LED 2H should be lit when associated wiring may be faulty.
The motor runs properly with travel automaic travel is required. If See the Wiring Diagram.
switch set to Manual. LED 2H does NOT light check Check and repair or replace if
the coil resistance of relay 2CR. necessary.
Normal resistance is 10,000
ohms.
The travel motor runs continuously 1. Observe LED 2H on Logic Board. 2. If LED 2H works correctly, the
when set to AUTOMATIC. LED 2H should only be ON if the contacts in relay 2CR may be
Start button has been presed. If stuck closed. Replace relay.
Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-18 TROUBLESHOOTING AND REPAIR H-18
OUTPUT PROBLEMS
The travel circuit breaker trips 1. While unit is traveling check the 1. If all tests are good the circuit
repeatedly. the travel motor armature cur- breaker may be faulty. Test or
rent. Normal current is 0.5 amps replace.
DC.
The travel motor runs at full speed 1. Remove power to unit and check 1. Perform the Travel Motor Test.
with no control. the resistance of travel speed
control rheostat (R6). Normal
Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-19 TROUBLESHOOTING AND REPAIR H-19
OUTPUT PROBLEMS
The travel motor runs with limited 1. Remove power to unit and check 1. Perform the Travel Motor Test.
speed. The control may be erratic. the resistance of travel speed
control rheostat (R6). Normal
resistance is 5000 ohms. Also
check R6 for smooth operation.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
LT-7 TRACTOR
H-20 TROUBLESHOOTING AND REPAIR H-20
LIGHT LOCATION IDLE INCH UP INCH DOWN START STOP BURNBACK GROUND
NO. MODE SWITCH SWITCH SWITCH SWITCH MODE LEAD
PRESSED PRESSED PRESSED PRESSED PROTECTOR
TRIPPED
1A CONTR. BD. ON
1B CONTR. BD. ON ON
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1C CONTR. BD. ON ON
1D CONTR. BD. ON ON ON ON ON
1E CONTR. BD. ON ON ON
2B LOGIC BD. ON
2C LOGIC BD. ON ON ON
2D LOGIC BD. ON* ON* ON* ON ON ON*
2E LOGIC BD. ON ON
2F LOGIC BD. ON ON ON ON ON
2H LOGIC BD. ON
2J LOGIC BD. ON
2K LOGIC BD. ON ON
2L LOGIC BD. ON
2M LOGIC BD. ON
3A VOLT BD. ON ON ON
3B VOLT BD. ON ON ON
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LT-7 TRACTOR
H-21 TROUBLESHOOTING AND REPAIR H-21
2K
LOGIC 2E 2M
TRACTOR 2C
LT-7 2H
L5927-2
2D
2J
2L
2F
2F
2L
2J
2D
L5927-2
LT-7 2H
TRACTOR 2C
LOGIC 2E 2M
2K
Return to Section TOC
Return to Master TOC
2B
3B
3A
3A
3B
Return to Section TOC
Return to Master TOC
1A
1C
1D 1B
1E
1E
1D 1B
1C
Return to Section TOC
CONTROL
Return to Master TOC
1A
L6959-2
LT-7 TRACTOR
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC H-22
NOTES
LT-7 TRACTOR
H-22
H-23 TROUBLESHOOTING AND REPAIR H-23
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
Return to Section TOC
Return to Master TOC
TEST DESCRIPTION
This procedure will aid the technician in determining if the Wire Drive Motor is functioning
properly
MATERIALS NEEDED
Misc. Hand Tools
0 to 90 vdc Power Supply
120 vdc Power Supply
Volt/Ohmmeter
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Return to Section TOC
Return to Master TOC
LT-7 TRACTOR
H-24 TROUBLESHOOTING AND REPAIR H-24
#539
E #541
B
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D #626
C
#627
TABLE H.3
TEST POINTS RESISTANCE DC VOLTAGE
Field Winding
#539
E #541
B
D #626
C
#627
LT-7 TRACTOR
H-25 TROUBLESHOOTING AND REPAIR H-25
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
Return to Section TOC
Return to Master TOC
TEST DESCRIPTION
This procedure will aid the technician in determining if the Travel Motor is functional.
MATERIALS NEEDED
Misc. Hand Tools
0 to 90 vdc Power Supply
120 vdc Power Supply (only required for older shunt wound motors).
Volt/Ohmmeter
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LT-7 TRACTOR
H-26 TROUBLESHOOTING AND REPAIR H-26
PROCEDURE
3. *Apply field voltage first (pins C and D) to the motor.
1. Remove the travel motor connector from the LT-7 See Figure H.6 and Table H.4
control box.
4. Slowly apply the armature voltage on pins A and
2. Using the ohmmeter measure the motor resistances B.(See Table H.4)
per Table H.4. Also see Figures H.5. and H.6*
5. The motor should run and the speed should vary
3. If the motor resistance test is good proceed to the with changes to the armature voltage.
Motor Applied Voltage Test.
6. If the travel motor does NOT run and change speed
MOTOR APPLIED VOLTAGE TEST correctly the motor or gear box may be faulty.
1. *Carefully connect the 110VDC supply (SUPPLY 7. *To stop motor REMOVE ARMATURE VOLTAGE
TURNED OFF) to pins C and D on the travel motor FIRST. (Pins A and B)
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TABLE H.4
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LT-7 TRACTOR
H-27 TROUBLESHOOTING AND REPAIR H-27
#594
C A
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#595
B
A
#595
#594
#647 #559
D A
C B
#561
#646
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LT-7 TRACTOR
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC H-28
NOTES
LT-7 TRACTOR
H-28
H-29 TROUBLESHOOTING AND REPAIR H-29
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
Return to Section TOC
Return to Master TOC
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the LT-7 Wire
Feed Motor.
MATERIALS NEEDED
Misc. Hand Tools
Return to Section TOC
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Return to Section TOC
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LT-7 TRACTOR
H-30 TROUBLESHOOTING AND REPAIR H-30
Holder
C
Brush
A E B
Flux Hopper
Mounting Inspection
Assembly Plate (D)
A E B
Brush
C
Holder
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Motor
Cable
LT-7 TRACTOR
H-31 TROUBLESHOOTING AND REPAIR H-31
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
Return to Section TOC
Return to Master TOC
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the LT-7 Travel
Motor
MATERIALS NEEDED
Misc. hand tools
Return to Section TOC
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Return to Section TOC
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LT-7 TRACTOR
H-32 TROUBLESHOOTING AND REPAIR H-32
.007 Shim
Cover
Rear View Shunt
Front View
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Cable
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of Motor
Strain Mounting
Relief
Roll Pin
Drive Gear
Guard Pinion Gear
.007 Shim
Drive
Gear
1. Disconect the Control Cable and Weld cables from 1. Loosely mount the new Travel Motor using the three
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2. Remove the Drive Gear Guard and Cable Strain 2. Make sure that the pinion gear of the new motor
Relief and save for reassembly. assembly is fully engaged with the Drive gear on the
shaft and with a piece of .007 shim material
3. Remove the Shunt Cover to gain access to the between the engaged gears.
Travel Motor mounting bolts.
3. Tighten all three mounting bolts.
4. Remove the travel motor by first removing the two
easily accesible bolts then using an open end 4. Using a .125/.129 bit, drill through the existing hole
wrench, simultaneously loosen the third bolt while in the frame into the motor flange and insert the roll
pulling the motor away from the frame. pin to lock the motor in place. See Figure H.8.
5. Remove the 1/8 roll pin from the frame or the motor 5. Replace the shunt cover being certain that none of
and save with the mounting bolts for reassembly. If the leads are loose or pinched.
the roll pin is damaged during removal, obtain a
new one (T9967-8). See Figure H.8. 6. Replace ther Cable Strain Relief and the Drive Gear
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Guard.
LT-7 TRACTOR
H-33 TROUBLESHOOTING AND REPAIR H-33
X AM
NIM
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MIN
MAX
CALIBRATION PROCEDURE:
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1. Remove the input power from the LT-7 and take If it travels further than 26, adjust the MAX
the side cover off of the Travel Control Box. trimmer counter clockwise and re-test.
2. Locate the MAX and MIN trimmers on the Travel If it travels less than 23, adjust the MAX
Control PC Board. See Figure H.9. trimmer clockwise and re-test.
3. Dis-engage the travel mechanism and apply power 8. Turn the travel OFF and set the Travel Speed
to the LT-7. Control to Minimum. Start the travel and measure
the distance traveled in 1 minute. It should be .6 to
4. Turn the Travel Switch to MANUAL TRAVEL and 2.00 inches.
with the Travel Speed set to ~ 50 IN/MIN, allow the
motor to warm up for a few minutes. If it travels further than 2, adjust the MIN
trimmer counter clockwise and re-test.
5. Turn the Travel Switch to OFF. Engage the drive
mechanism and set the Travel Speed Control to If it travels less than .5, adjust the MIN
trimmer clockwise and re-test.
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Maximum.
6. Slightly load the LT-7 by dragging a length of 9. Repeat steps 7 and 8 as necessary to ensure
Control Cable and/or Welding Cable. proper calibration.
7. Turn the travel on and measure the distance trav- 10. Turn off the input power and replace the Travel
eled in 30 seconds. It should be 23 to 26 inches. Control Box cover.
LT-7 TRACTOR
H-34 TROUBLESHOOTING AND REPAIR H-34
To run a functional test of the LT-7 Tractor it will be nec- 3. Press the Inch Up Switch and see that the dtive
essary to provide a source of 120vac to the Control rolls turn in the proper direction.
Box. This can be accomplished in any of several ways.
4. Press the Start Switch and observe the follow-
1. Connect the LT-7 to a compatible Lincoln Power ing:
Source.
Apply power to the LT-7 using one of the methods d. See that the travel motor works according to
described above the Travel Controls and that the travel speed
is adjustable.
1. Check the LEDs on the PC Boards to see that 5. Press the Stop Switch and disconnect the input
the Idle Mode is correct. See Table H.5. power.
2. Press the Inch Down Switch and see that the If any of the functions are not as described check the
drive rolls turn in the proper direction. Troubleshooting Guide for possible solutions.
LT-7 TRACTOR
H-35 TROUBLESHOOTING AND REPAIR H-35
LIGHT LOCATION IDLE INCH UP INCH DOWN START STOP BURNBACK GROUND
NO. MODE SWITCH SWITCH SWITCH SWITCH MODE LEAD
PRESSED PRESSED PRESSED PRESSED PROTECTOR
TRIPPED
1A CONTR. BD. ON
1B CONTR. BD. ON ON
1C CONTR. BD. ON ON
1D CONTR. BD. ON ON ON ON ON
1E CONTR. BD. ON ON ON
2B LOGIC BD. ON
2C LOGIC BD. ON ON ON
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2E LOGIC BD. ON ON
2F LOGIC BD. ON ON ON ON ON
2H LOGIC BD. ON
2J LOGIC BD. ON
2K LOGIC BD. ON ON
2L LOGIC BD. ON
2M LOGIC BD. ON
3A VOLT BD. ON ON ON
3B VOLT BD. ON ON ON
Head
Wire Feed
Straightener
Wire
70
START
60
STOP
105
50
LT-7 TRACTOR
15 30
40
20
0
VOLTS
DC
05
LINCOLN WELD
SOLID STATE
REVERSE
01
20
30
04
DC
VOLTAGE DOWN
FORWARD
INCH
OF TRAVEL
DIRECTION
CURRENT
INCH
UP
MANUAL TRAVEL
AMPERES
OFF
Weld Wire
0
DC
01
AUTOMATIC TRAVEL
2
4
6
8
Code No.
POWER
ON
CONTROL
Weld Wire
Code No. ON
CONTROL
6
AUTOMATIC TRAVEL
4 Serial No. OFF
POWER
2
OFF DC
AMPERES
10
0
MANUAL TRAVEL
DIRECTION INCH
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CURRENT UP
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OF TRAVEL
FORWARD
INCH
VOLTAGE DOWN
30
REVERSE 20
DC
10
40
20 DC LINCOLN WELD
15 30 VOLTS SOLID STATE
50
0
40 LT-7 TRACTOR
10
50
STOP
60
5 70
START
Wire
Straightener
Wire Feed
Head
Wire
Reel
Contact
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Electrode
Nozzle
Connections
Shunt and Reed
Switch
Under Cover
LT-7 TRACTOR
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC H-36
NOTES
LT-7 TRACTOR
H-36
Return to Master TOC J-1 TABLE OF CONTENTS - DIAGRAM SECTION J-1
LT-7 TRACTOR
J-2 ElECTriCal Diagrams J-2
WiriNg Diagram - C0DEs BElOW 9100 - l5879
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632A 2 OHM
531A 250 OHM
2 OHM
510 VARIABLE VOLTAGE
TRAVEL P.C. BOARD
5879
25 631 510 P.C. BOARD
610
1 /2 AMP SLOW 531A 2
L
TRAVEL 539 10
BLOW FUSE
CONTROL
SHT.
525 4
NO.
SWITCH MANUAL 532
531 532 1
OFF
510
3 2CR 67 9
*
*
1
12-10-76
AUTO 625 CONTROL P.C. BOARD 21 3
*
632 2
LT-7 TRACTOR
637 11
3 532
589 1 8 6 9 7 10 12 1 2 11 2 592 5
.8 AMP CIRCUIT 4
SUP'S'D'G
AMP FUSE N.A.
561 4 632A 10
BREAKER 635 12
559 5 632
636 8
625 539 532 626
6 2 610
528 7
510 631 541 627 510
1 /2 AMP SLOW
656 657 562 6
647 TRAVEL RELAY BLOW FUSE
*
TRAVEL
*
DIRECTION
REF.
SUBJECT
646 SWITCH
EQUIP.
TYPE
1 2 3 4 5 6 7 8 9 CONTACTOR RELAY
5 4 8 1 7 9 3 2 6
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THP
TRAVEL SPEED
3 1CR
CONTROL 510 LOGIC P.C. BOARD
CHK
657 532 572
6-12-92
682 1
539
NONE
572
DATE
563
*
2
SCALE
2
8 9 10 12 2 5 7 11 3 6 1 4
DR DAD/JLV
10 11 2 3 9 1 8 7 6 4 12
561 647
559 646
CONTROL CABLE
4CR 532
TRAVEL MOTOR TO POWER SOURCE
539 563
CONNECTOR 539 WIRE FEED
4 32 75 77 541 627
A B C D MOTOR
2 31 21 76 GND 541 539 626
CONNECTOR
559 646 A B C D E F G H I GROUNDING A B C D E
TERMINAL
561 647 531
LEAD STRIP
532
PROTECTOR
LIGHT
31 21 76 GND 626 GND
6-25-82M
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4-29-77A
11-4-77J
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*
STOP
INDICATES CONNECTOR CAVITY NUMBERS GROUND
582
A ND IS
THIS SHEET CONTAINS PROPRIETARY INFORMATION
START
539 ARM 541
O W NE D BY
(COMPONENT SIDE OF P.C. BOARD) 531 REED SWITCH 67 517
539 INCH
76 UP
NOTES: 517 67 593
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-
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75
N.A. WHEN CONTROLS ARE USED WITH R3S POWER SOURCES
+
UNITS SHIPPED WITH CONNECTION MADE AT PIN "H". 31 32 ELECTRODE LEAD WORK LEAD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lT-7 TraCTOr
J-3 ELECTRICAL DIAGRAMS J-3
WIRING DIAGRAM - CODES ABOVE 9100 - L7460
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Return to Master TOC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
LT-7 TRACTOR
J-4 ElECTriCal Diagrams J-4
CONNECTiON Diagram - CODEs BElOW 9100 - m13514
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Return to Master TOC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lT-7 TraCTOr
J-5 ElECTriCal Diagrams J-5
CONNECTiON Diagram - CODEs aBOvE 9100 - m15342
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Return to Section TOC
Return to Master TOC
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Return to Master TOC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
lT-7 TraCTOr
J-6 ElECTriCal Diagrams J-6
sChEmaTiC - COmplETE maChiNE - CODEs BElOW 9100 - g1452
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1452 G
SHUNT
ELECTRODE LEAD
WORK LEAD TO TO POWER SOURCE
LED 2M
POWER SOURCE R227 R214 510(110V)
WORK 515 (15V)
21
R215
R236
R216
D210 D206
525 (24V) LED 2B R237
LED 2C 12 X201 X201 2CR 1CR
D211 X203
563 R233 4
D212 D f 6
11 13 B
21 517 67 13 12 589
R306 D202 X201 682
D307 D306 532 DZ204 DZ205
D301 5
C214 10
R315
- + - + VARIABLE DZ304 START
581 R229 C
R201
R230
R317
R309
C303 SWITCH 8
VM AM C203 9
VOLTAGE D302
67
4
24
1
Q201 S5
C201 C209 9 X202
Q302 582 X203 LED LED 2K
VAC R234
P.C. BOARD PT301 C d R224 2H
R312
R302
R307
5 3 DZ201 S6 9
TP STOP 8 8
10
301 T301 C202 Q202
R318
C305 SWITCH C211
D311 539
QU301 + C301 D308 D309 531A 562 D218 X205
515 (15V) X202 Q204
OCI301 D205 12 X205 10
R308 D312 5
75 D 6 C C212
R313
POWER SOURCE D310 11 X205 4 B 8
R228
R203
13 9
R202
R319
CONTACTOR X203 X204
OUTPUT CONTROL LED LED 3A D201 12
C309 5
R225
R218
S301 12
R205
DZ302 DZ303 VV DELAY C D
3B
R208
R2
76 TP CV LED D
ADJ. 6 11
R304
302 13
637 2D 13
X202
R314
C302 C310 1
R206
539
R305
77 DZ301 D213
R207
DZ306 4 1 C307 + Q303 A
6 C210 2 3
R311
R320
PT301 L201
R303
2 CONTACTOR RELAY OCI301 DZ305 D209
5 Q301 X202
C304 OCI 2 C306 +
1CR R316 4 X203
R310
302 QU201 R235
R204
21 R301
X203 B e R219
C204
R232
D303 D304 D305 L H 6 11
4 10
a 5
563 V 1 X205
C308 2 2 X204
5
N.C. C205
4CR 528 A
C208 3 4 B
539 1 6
3CR
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CONTROL BOX
Return to Master TOC
D111
R104
31 531 531A R1 631
S1 Q101
525 (24V)
531 586
Q102
R123
PT105 D106
C114
525
D113
531 TRAVEL 561
DZ101 D108
GND
R120
R209
R127
D117
R119
LIGHT RECEPTACLE P.C. BOARD
657 541 R105
(1 AMP MAX.) TP101
TRAVEL SCR102 636
D116
SCR101
R226
647 MOTOR C103 C104 C116 QU103
635
R133 629
PT104
TRAVEL C101 PT PT LED
R109
DZ202
CONTROL 559 C113 101 101
MANUAL 2E PT104
R113
D208 D207
R114
R118
SWITCH D204 PT105
R124
R106
TRAVEL TRAVEL D108 C119 C120
25 641
DIRECTION MOTOR WIRE FEED
OFF S2 Q105
SWITCH FIELD MOTOR FIELD 627
C121 C108
R223
AUTO 642
R3
D112
571 LED C118
C102 C207
R210
SCR103 SCR104 D103 587
LED 1C 1E 629
R107
625
LED 634
D107 D203
1A
R231
WIRE FEED
R111
646 TRAVEL D216
INCH
R222
SPEED
R6
572 626
R126
0.8 AMP C122
SPEED D109 TRIMMER CONTROL
R111
CIRCUIT BREAKER R102
R125
656 CONTROL
R101
Q107 Q106
2CR Q205
593 LED 2L 592
Q203
R5 632A 632 632 574
LED 1D
QU101 Q103 Q108
R110
R132
R121
R115
S3 S4
R131
R112
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F101
R117
R122
R220
R212
DZ102 C215
R221
D110
LED
32 532 Q104 INCH UP INCH
R128
PT 1B D114 C213 DOWN
S1 D101 D102 SWITCH
R129
101 SWITCH
C110
CONTROL POWER
R213
C106 C107 C117
SWITCH
586
539 539
LED 2F
WIRE FEED MOTOR
DZ203 C206
SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS. VARIABLE VOLTAGE CIRCUIT
FOR VARIABLE VOLTAGE P.C. BOARDS L5394-2 OR HIGHER
CONTROL CIRCUIT
USE M16966 SCHEMATIC FOR COMPONENT VALUES AND
C101 .47 MFD R101 80 OHM 12 W Q101 2N5655
CiRCUIT CONNECTIONS.
LOGIC CIRCUIT
C102 50 MFD R102 68K OHM Q102 MJ3029
C103 .047 MFD R104 10K OHM 2 W Q103 2N4123 C201 .02 MFD R201 1.5K OHM R234 470 OHM C301 2 MFD R316 33K OHM
.047 MFD R105 39K OHM Q104 C202 2 MFD R202 4.7K OHM R235 470 OHM C302 .1 MFD R317 10K OHM
C104 2N4123
C203 .02 MFD R203 15K OHM R236 4.7K OHM C303 .01 MFD R318 560 OHM
C106 .047 MFD R106 4.7K OHM Q105 2N4123
C204 10 MFD R204 47 OHM R237 330 OHM C304 .02 MFD R319 2.7M OHM
C107 .1 MFD R107 15K OHM Q106 2N5816
C205 10 MFD R205 10K OHM C305 .01 MFD R320 100 OHM COMPONENTS NOT ON P.C. BOARD
C108 1 MFD R108 22K OHM Q107 2N5816 C206 50K OHM TRIMMER
.02 MFD R206 C306 2 MFD
}
C110 1 MFD R109 10K OHM Q108 2N4123 C207 50 MFD R207 1.5K OHM C307 .47 MFD R1 2 OHM 50 W
C113 .15 MFD R110 1.5K OHM C208 2 MFD R208 1K OHM X201 QUAD 2 INPUT C308 .22 MFD LED 3A RED LIGHT R2 10K OHM 2 W POWER SOURCE
C209
}
C114 .15 MFD R111 5K OHM TRIMMER 4.7 MFD R209 10K OHM NANDGATE C309 .02 MFD LED 3B EMITTING DIODE OUTPUT CONTROL
C210 C310 .01 MFD
C116 .047 MFD R112 4.7K OHM R210 5K OHM TRIMMER X202 QUAD 2 INPUT R3 5K OHM 2 W WIRE FEED SPEED CONTROL
THRU .02 MFD
R211 1K OHM R4 250 OHM 25 W
}
C117 .02 MFD R113 22K OHM QU101 2N6027 NANDGATE
C215 OC1301 OPTO-ISOLATOR
R212 2.7K OHM X203 HEX INVERTER R5 2 OHM 25 W
C118 .02 MFD R114 10K OHM QU103 UJT
R213 47K OHM D301 OC1302 OPTO-ISOLATOR R6 5K OHM 2 W TRAVEL SPEED CONTROL
X204 QUAD 2 INPUT A.N.S.I. ELECTRICAL SYMBOLS PER E1537.
C119 .02 MFD R115 100 OHM THRU 1 A
D201 R214 4.7K OHM
.02 MFD R117 47 OHM NANDGATE
C120 THRU R215 D304
4.7K OHM
}
X205 QUAD 2 INPUT Q301 2N4123 S1 DPST CONTROL POWER SWITCH
}
C121 1 MFD R118 6.8K OHM D213 R216 4.7K OHM N.A. TO OPERATE UNIT WITHOUT VARIABLE VOLTAGE BOARD JUMPER 637 TO 539 AND 635 TO 636.
1 A NANDGATE Q302 2N5815 S2 SPDT TRAVEL CONTROL SWITCH
C122 .02 MFD R119 6.8K OHM D216 R217 4.7K OHM D305
Q303 MPS A13 S3 SPST INCH UP SWITCH N.B. X201 THRU X205 - PIN 7 CONNECTED TO 539, PIN 14 CONNECTED TO 515
THRU 1 A
R120 680 OHM LED 1A D217 R218 1.5K OHM
S4 SPST INCH DOWN SWITCH
RED D218 R219 D312 N.C. WHEN CONTROLS ARE USED WITH R3S POWER SOURCES OF THE TYPE WHICH USES TAPS CONNECTED
R121 2.7K OHM LED 1B 2.7K OHM QU301 UJT
D101 16 A S5 SPST START SWITCH
LIGHT WITH A TRIANGLE PLATE FOR MAJOR VOLTAGE ADJUSTMENTS, JUMPER TO BE CONNECTED TO
Return to Section TOC
}
EMITTING LED 2B R221 1.5K OHM TP301 TRANSIENT PROTECTOR PIN "L". FOR ALL OTHER POWER SOURCES JUMPER TO BE CONNECTED TO PIN "H".
R123 100 OHM LED 1D R301 47K OHM S7 DPDT (REV.) TRAVEL DIRECTION SWITCH
D103 16 A
DIODE THRU R222 1K OHM TP302 TRANSIENT PROTECTOR
R124 100 OHM LED 1E R302 3.3K OHM 2 W
D104
LED 2F R223 10K OHM R303 6.8K OHM
R125 10K OHM RED LIGHT 1CR SPST 110 VDC COIL
THRU DZ201 16V PT301 PULSE TRANSFORMER
}
LED 2H R224 2.7K OHM R304 68K OHM
1 A R126 680 OHM EMITTING DIODE 2CR SPST 110 VDC COIL
D114 LED 2J DZ202
R225 1.5K OHM R305 100K OHM
D116 R127 4.7K OHM THRU S301 SPDT TOGGLE SWITCH 3CR REED SWITCH ACTUATED BY NOTE: SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THRU 3V R306 4.7K OHM 2 W
R226 6.8K OHM WELDING CURRENT
D117 R128 47K OHM SCR101 8A 600V LED 2M THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
DZ205 R307 100 OHM
R227 1.5K OHM T301 24V TRANSFORMER 4CR REED SWITCH ACTUATED BY FAULT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
R129 47K OHM SCR102 8A 600V R308 10K OHM TRIMMER
R228 4.7K OHM CURRENT THRU GROUNDING LEAD
DZ101 25V R131 10K OHM 2 W SCR103 12A 400V R309 15 OHM
Q201 2N5655 DZ301 5.1V
R229 100 OHM R310 75 OHM TO POWER SOURCE FRAME.
DZ102 3V R132 10K OHM SCR104 12A 400V Q202 2N5657 DZ302 10V
R230 100 OHM R311 68 OHM
R133 27K OHM Q203 2N4123 DZ303 25V
R231 100 OHM R312 5.6K OHM 2 W
Q204 2N5657 DZ304 15V THE LINCOLN ELECTRIC CO.
EQUIP.
LT-7 TRACTOR
TP101 TRANSIENT PROTECTOR PT101 PULSE TRANSFORMER R232 47 OHM R313 6.8K OHM TYPE
Q205 0.5A 300V DZ305 3V CLEVELAND, OHIO U.S.A.
F101 1/2A SLOW BLOW FUSE PT104 PULSE TRANSFORMER R314 10K OHM OPERATING SCHEMATIC
R233 100 OHM DZ306 3V SUBJECT
R315 1K OHM 12 W SCALE NONE
UJT
F102 2/10A FUSE PT105 PULSE TRANSFORMER QU201
G
t SHT.
DR DAD/JLV DAT E 6-4-92 C HK THP REF. SUP'S'D'G G1359
NO. 1452
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lT-7 TraCTOr
J-7 ElECTriCal Diagrams J-7
sChEmaTiC - COmplETE maChiNE - CODEs aBOvE 9100 - g1790
Return to Section TOC
Return to Master TOC
G1790 ENGINEERING CONTROLLED CHANGE DETAIL: TRAVEL CIRCUIT, ADDED C412, R419 AND D412 AND REVISED GRAPHICS
MANUFACTURER: No R403 THRU R405, R410, Q401 AND Q402, REVISED VALUES
Return to Section TOC
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D419
R419
+
C412
Return to Section TOC
Return to Master TOC
FOR CONTROL P.C. BOARDS L6959-2 OR HIGHER USE L8943 SCHEMATIC FOR LOGIC P.C. BOARDS L5927-2 OR HIGHER USE L9015 SCHEMATIC FOR VARIABLE VOLTAGE P.C. BOARDS L5394-2 OR HIGHER USE M16966
FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS. FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS. SCHEMATIC FOR COMPONENT VALUES AND CIRCUIT CONNECTIONS.
CONTROL CIRCUIT LOGIC CIRCUIT VARIABLE VOLTAGE CIRCUIT TRAVEL CIRCUIT COMPONENTS NOT ON P.C. BOARD
C101 .47 MFD R101 80O, 12W R133 27K O C201 .02 MFD QU201 UJT R232 47.5 O C301 2 MFD R316 33K O C401 2 MFD D401 1A R1 2 O, 50W
C102 50 MFD R102 68K O C202 2 MFD R233 100 O C302 .1 MFD R317 10K O C402 10 MFD D402 1 A, 1000V R2 10K O, 2W POWER SOURCE OUTPUT CONTROL
C103 .047 MFD R104 10K O, 2W Q101 2N5655 C203 .02 MFD R201 1.5K O R234 475 O C303 .01 MFD R318 560K O C403 .005 F D403 1 A, 1000V R3 5K O, 2W WIRE FEED SPEED CONTROL
C104 .047 MFD R105 39K O Q102 MJ3029 C204 10 MFD R202 4.75K O R235 475 O C304 .02 MFD R319 2.7M O C404 10 MFD D404 16 A R4 250 O, 25W
C106 .047 MFD R106 4.7K O Q103 2N4123 C205 10 MFD R203 15K O R236 4.75 O C305 .01 MFD R320 100 O C405 .1 MFD D405 16 A R5 2 O, 25W
ELECTRICAL SYMBOLS PER E1537
C107 .1 MFD R107 15K O Q104 2N4123 C206 .02 MFD R204 47.5K O R237 332 O C306 2 MFD C406 .01 MFD D406 16 A R6 5K O, 2W TRAVEL SPEED CONTROL
C108
C110
1 MFD
1 MFD
R108
R109
22K O
10K O
Q105
Q106
2N4123
2N5816
C207
C208
50 MFD
2 MFD
R205
R206
10K O
50K O TRIMMER X201 QUAD 2 INPUT NANDGATE
C307
C308
.47 MFD
.22 MFD
LED 3A
LED 3B
} RED LIGHT
EMITTING DIODE
C407
C408
.047 MFD
.047 MFD
D409
D410
1A
1A S1 DPST CONTROL POWER SWITCH
NOTES:
N.A. TO OPERATE UNIT WITHOUT VARIABLE VOLTAGE BOARD
}
C113 .15 MFD R110 1.5K O Q107 2N5816 C209 4.7 MFD R207 1.5K O X2O2 QUAD 2 INPUT NANDGATE C309 .02 MFD C411 .02 MFD D411 1A S2 SPDT TRAVEL CONTROL SWITCH JUMPER 637 TO 539 AND 635 TO 636.
C114 .15 MFD R111 5K O TRIMMER Q108 2N4123 C210 R208 1K O X203 HEX INVERTER C310 .01 MFD OCI301 OPTO-ISOLATOR C412 1 MFD D412 1A S3 SPST INCH UP SWITCH N.B. X201 THRU X205 - PIN 7 CONNECTED TO 539
C116 .047 MFD R112 4.7K O THRU .02 MFD R209 10K O X204 QUAD 2 INPUT NANDGATE OCI302 OPTO-ISOLATOR S4 SPST INCH DOWN SWITCH - PIN 14 CONNECTED TO 515
}
C117 .02 MFD R113 22K O QU101 2N6027 C215 R210 5K O TRIMMER X205 QUAD 2 INPUT NANDGATE D301 R401 10 K O TP401 TRANSIENT PROTECTOR S5 SPST START SWITCH N.C. WHEN CONTROLS ARE USED WITH R3S POWER SOURCES OF THE
C118 .02 MFD R114 10K O QU103 UJT R211 1K O THRU 1A Q301 2N4123 R402 22K O TP402 TRANSIENT PROTECTOR S6 SPST STOP SWITCH TYPE WHICH USES TAPS CONNECTED WITH TRIANGLE PLATE FOR
} }
C119 .02 MFD R115 100 O D201 R212 2.67K O L201 5.6mH D304 Q302 2N5815 R403 2.7K O S7 DPDT (REV.) TRAVEL DIRECTION SWITCH MAJOR VOLTAGE ADJUSTMENTS, JUMPER TO BE CONNECTED TO
}
C120 .02 MFD R117 47 O LED 1A RED THRU R213 47.5K O D305 Q303 MPS-A13 R404 162 O PT401 1:1:1 PULSE TRANSFORMER PIN "L". FOR ALL OTHER POWER SOURCES JUMPER TO BE CONNECTED
C121 1 MFD R118 6.8K O LED 1B LIGHT D213 1A R214 4.75K O DZ201 16 V. THRU 1A R405 1.5K O, 15W 1CR SPST, 110 VDC COIL TO PIN "H".
}
C122 .02 MFD R119 6.8K O LED 1C EMITTING D216 R215 4.75K O DZ202 D312 QU301 UJT R406 15K O DZ401 20 V 2CR SPST, 110 VDC COIL
R120 680 O LED 1D DIODE D217 R216 4.75K O THRU 3 V. R407 4.7K O 3CR REED SWITH ACTUATED BY WELDING CURRENT
NOTE: SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD
D101 16 A R121 2.7K O LED 1E D218 R217 4.75K O DZ205 R301 47 K O TP301 TRANSIENT PROTECTOR R408 4.7K O, 4W SCR401 12A 400V SCR 4CR REED SWITH ACTUATED BY FAULT CURRENT THRU MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A
D102 16 A R122 47K O R218 1.5K O R302 3.3K O, 2W TP302 TRANSIENT PROTECTOR R409 4.7K O SCR402 12A 400V SCR GROUNDING LEAD TO POWER SOURCE FRAME. COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
} }
D103 16 A R123 100 O SCR101 8A, 600 V. LED 2B R219 2.67K O R303 6.8K O R410 1K O TRIMMER COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON
D104 R124 100 O SCR102 8A, 600 V. THRU RED R220 4.75K O R304 68K O PT301 PULSE TRANSFORMER R411 20K O TRIMMER Q401 2N4401 CODE NUMBER.
THRU R125 10K O SCR103 12A, 400 V. LED 2F LIGHT R221 1.5K O R305 100K O R412 27K O Q402 2N4401
D114 1A R126 680 O SCR104 12A, 400 V. LED 2H EMITTING R222 1K O R306 4.7K O, 2W S301 SPDT TOGGLE SWITCH R413 47K O
D116 R127 4.7K O LED 2J DIODE R223 10K O R307 100 O R414 2.2K O QU401 2N6027
D117 R128 47K O THRU R224 2.67K O R308 10K O TRIMMER T301 24V. TRANSFORMER R415 10K O
Return to Section TOC
DZ101 25 V R131 10K O, 2W R226 6.81K O R310 75 O DZ301 5.1V R417 2.7K O, 4W
DZ102 3 V R132 10K O Q201 2N5655 R227 1.5K O R311 68 O DZ302 10V R418 2.5K O, 5W
Q202 2N5657 R228 4.75K O R312 5.6K O, 2W DZ303 25V R419 3.3K O
TP101 TRANSIENT PROTECTOR PT101 PULSE TRANSFORMER Q203 2N4401 R229 100 O R313 6.8K O DZ304 15V
PT104 PULSE TRANSFORMER Q204 2N5657 R230 100 O R314 10K O DZ305 3V
F101 1/2A SLOW BLOW FUSE PT105 PULSE TRANSFORMER Q205 .5 A, 300 V. R231 100 O R315 1K O, 12W DZ306 3V
F102 2/10 A FUSE
PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND
ON 2 PLACE DECIMALS IS .02 in. ( 0.5 mm) NONE
EQUIPMENT TYPE: LT-7 TRACTOR 1
1 OF ___
PAGE ___
ON 3 PLACE DECIMALS IS .002 in. ( 0.05 mm) DRAWN BY: fivory DOCUMENT
OPERATING SCHEMATIC
DOCUMENT
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
IF PRINTED
@ A1 SIZE SUBJECT: NUMBER: REVISION:
ENGINEER: -
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: -
UNITS:
INCH
MATERIAL
DISPOSITION: UF APPROVAL
DATE:
2-15-2008 PROJECT
NUMBER: CRM37981
REFERENCE:
-
G1790 B
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lT-7 TraCTOr
J-8 ElECTriCal Diagrams J-8
pC BOarD assEmBlY - CONTrOl BOarD - l6959-2
Return to Section TOC
Return to Master TOC
L6959-2 ENGINEERING CONTROLLED CHANGE DETAIL: CALLED OUT NOTE N.G.1 ITEM QTY PART NUMBER DESCRIPTION
MANUFACTURER: No 1 1 SEE BLANK INFO PC BOARD BLANK
2 2 CF000005 #6-32HN
2 S14008-7 HEAT SINK,
2 CF000003 #6-32 X .375RHS
3
2 E106A-13 LOCK WASHER
2 T13746 #6-32HN - NICKEL
4 .5 OZ. E2861 SEALANT
P.C. BOARD INFORMATION 5 1 T13770-2 CABLE TIE
MAKE FROM S19399 (MAKES 4 BOARDS PER PANEL,
6 3 E2387-#20-2.00 JUMPER
R1 SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
1 S14367-1 DIODE & HEATSINK ASSEMBLY
BLANK PART NUMBER L6959-S N.A.7 7
LUG 1 CF000354 #10-32HN
9 AS REQ'D E1868 THERMAL COMPOUND
PCB SEALANT LEAD REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
QU1
D7
N.A.1, N.A.5
R18 R32 R12
SCR4
R14 R36
C13, C14 2 S13490-96 CAPACITOR,PEMF,0.15,200V,10%
Return to Section TOC
R10 R5 R17
R63 C4
CONTROL
C17, C18, C19, C20, C21, C23 6 S16668-5 CAPACITOR,CEMO,.022,50V,20%
R11
R15 R33
C6
D9
Q3
Q4
LED1A D14 C10
C7
SCR3
R3 7
DZ1 1 T12702-41 ZENER DIODE,5W,24V,5%,1N5359B
PT1
C3
L ED1D L ED1C
L ED1B
N.E.1 J9 1 T13160-64 CONNECTOR,PCB,PLUG,9-PIN
C13
R4 1
ALTERNATE N.E.1 J12 1 T13160-22 CONNECTOR,PCB,PLUG,12-PIN
R2
R3 9
R2 4
Q10
COMPONENT LED1A, LED1B, LED1C, LED1D,
R3 8
5 T13657-2 LED,T-1,3/4,RED,HLMP-3003
TP1
LED1E
N.A.3, N.A.4
C2
J9
2.90 PT1, PT4, PT5 3 T12737-2 TRANSFORMER,PULSE,3-WINDING,1:1:1
Q1 1 T12704-16M3A TRANSISTOR,NPN,T225,0.5A,250V,2N5655
C2 0
PRIMARY
D1
D3
D2
PT4
Q2 1 S15306 TRANSISTOR
COMPONENT Q9
R62
QU3 DZ1 R52
R51
R53
R54 6 Q3, Q4, Q5, Q6, Q7, Q8, Q9, Q10 8 T12704-68 TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
C16
C23 R50 R55
R20 R49 R31
LED1E QU1, QU3 2 T12707-4 TRANSISTOR,PUT,TO92,2N6027
R59 & R60 5
R40
R1 1 T12300-88 RESISTOR,WW,20W,50,5%
7 N.A.7
D4
R19
C1
SCR1
J 12
R2, R41 2 S19400-1333 RESISTOR,MF,1/4W,133K,1%
R34 D5
C18
SCR2
R4, R31, R43, R44, R45, R46, R47,
DETAIL A XXXXXXX R48, R49, R50, R51, R52, R53, R54, 16 S19400-2002 RESISTOR,MF,1/4W,20.0K,1%
R2 7
R2 9
R2 5
R2 8
R2 6
R5 9
C17
C19
C14
XXXXXXX R55, R61
B
X X R5, R8, R13 3 S19400-2212 RESISTOR,MF,1/4W,22.1K,1%
R4 8
R4 7
R4 6
R4 5
Q2
X X
R5 8
X N.A.2
Q8
E
Q7
X XX X R7 1 S19400-1502 RESISTOR,MF,1/4W,15.0K,1%
PT5
X XX X
Q6 R60
R9, R14, R22, R25, R32, R38, R63 7 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
R2 3
R1
X XX X R10, R34 2 S19400-1501 RESISTOR,MF,1/4W,1.50K,1%
D13
R6 1
R4 3
R4 4
D11
R4
Q1
.25 X XX X X 1 R11 1 T10812-36 TRIMMER,ST,1/2W,5K, 10%,LINEAR
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N.A.9 MOUNT COMPONENT WITH THE RESISTOR LUGS AGAINST THE PC BOARD AS SHOWN IN DETAIL B.
}
N.E.1 DO NOT COAT WITH ENCAPSULATION MATERIAL.
TEST PR E2209-C
N.E.2 COAT CABLE TIE AROUND CAPACITOR WITH ENCAPSULATION MATERIAL.
MANUFACTURED AS: SCHEMATIC REFERENCE: L8943-2S0
N.E.3 ENCAPSULATION MATERIAL TO FLOW UNDER CAPACITOR.
N.E.4 BEFORE ENCAPSULATION, PLACE A BEAD OF ITEM 4 TO COVER THE LEADS UP TO THE BOTTOM OF THE COMPONENT, BUT NOT FOR PARTS ORDERS:
L6959-2S0
Return to Section TOC
Return to Master TOC
}
N.E.5 BEFORE ENCAPSULATION, PLACE A BEAD OF ITEM 4 TO COVER THE LEADS AND ENDS OF THE COMPONENT. COMPONENT TO BE RESISTORS = OHMS
MOUNTED AGAINST THE PC BOARD. IDENTIFICATION CODE E4018 AFTER PROPER TRIMMING HAS BEEN DONE.
INCLUDE T11590-90 AND S24590-1PRINT.
N.E.6 COMPLETELY COVER THE LEADS, LUGS, AND LOWER ENDS OF THE RESISTOR WITH ITEM 4. SEE DETAIL B.
N.E.7 DO NOT COAT HEATSINK WITH ENCAPSULATION MATERIAL .50 .12 ABOVE COMPONENT SIDE SURFACE. ENCAPSULATION PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MATERIAL MAY RUN INTO RESTRICTED AREA, BUT NO MORE THAN 10% OF SURFACE AREA MAY BE COVERED. MANUFACTURING TOLERANCE PER E2056 CONTROL: SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
CLEVELAND
1:1
EQUIPMENT TYPE: LT TRACTOR 1
1 OF ___
PAGE ___
ON 3 PLACE DECIMALS IS .002 in. ( 0.05 mm) DRAWN BY: fivory IF PRINTED DOCUMENT DOCUMENT
GENERAL NOTES:
N.G.1 CAUTION: THIS ASSEMBLY IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454 BEFORE HANDLING.
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: -
@ A2 SIZE SUBJECT: CONTROL P.C. BOARD ASSEMBLY NUMBER: REVISION:
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: DRS
UNITS:
INCH
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE: -
PROJECT
NUMBER: CRM41787
REFERENCE:
-
L6959-2 H.01
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. individual printed Circuit Board Components are not available from lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
lT-7 TraCTOr
J-9 ElECTriCal Diagrams J-9
pC BOarD assEmBlY - lOgiC BOarD - l5927-2
Return to Section TOC
Return to Master TOC
5927-2
R10 2F
R6
L
LOGIC P.C. BOARD ASSEMBLY
SHT.
NO.
INCH CONTACTOR DELAY
LT TRACTORS
C5 C4
L5927-1
2J
2L
SUP'S'D'G
C8
C7
2D
L5927-2 2H
LT-7
TRACTOR
TYPE
EQUIP.
REF.
LOGIC 2M
SUBJECT
2C
2K
2E
Return to Section TOC
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CHK LJP
C2
F RA F RA
DATE 10-28-92
FULL
2B
SCALE
563
J1 J2
FI DR
0 0
RESISTORS = OHMS
CAPACITORS = MFD/VOLTS
12-3-92B
10-29-93
3-5-93G
5-7-93
~.04
5.70
Return to Section TOC
5.48
1 1 L5927-F PC. BOARD BLANK
L5927-2F1
1
IDENTIFICATION CODE
L5927-2 MAKE PER E1911
LT-7
TRACTOR ENCAPSULATE WITH E1844
LOGIC
TEST PER E2209-L
1.20
NOTES:
CAD
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. individual printed Circuit Board Components are not available from lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
lT-7 TraCTOr
J-10 ElECTriCal Diagrams J-10
sChEmaTiC - variaBlE vOlTagE BOarD - m16966-2k0
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
lT-7 TraCTOr
J-11 ElECTriCal Diagrams J-11
pC BOarD assEmBlY - variaBlE vOlTagE BOarD - l5394-2
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L5394-2 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED OCI2, BLANK, MANUAFACTURED AS, IDENTIFICATION CODE AND SCHEMATIC REFERENCE PART NUMBERS ITEM (USED WITH)* QTY PART NUMBER DESCRIPTION
MANUFACTURER: No REMOVED C10 CAPACITOR AND R24 RESISTOR 1 1 L5394-K PC BOARD BLANK
2 (Q2)* 1 S20590-1 HEAT SINK,SLIP ON,FOR TO-220
N.A. 3 1 S14165-204 PLUG AND LEAD ASSEMBLY
2 CF000048 #8-32X.25RHS
4
2 CF000042 #8-32HN
MAKE FROM S19399 (MAKES 9 BOARDS PER PANEL, C2, C4, C6, C7, C13, C17 6 S16668-11 CAPACITOR,CEMO,0.1, 50V,10%
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION) C3, C5, C8, C14, C15,
8 S16668-5 CAPACITOR,CEMO,.022,50V,20%
C16, C18, C19
BLANK PART NUMBER L5394-K C9 1 T11577-32 CAPACITOR,PEF,.01,200V,10%
C11 1 S13490-68 CAPACITOR,ALEL,2,150V,+75/-10%
D1, D2, D3, D4, D5, D10,
7 T12199-1 DIODE,AXLDS,1A,400V
D15
D6, D7, D8, D9, D11, D12,
8 T12199-4 DIODE,AXLDS,1A,600V
D13, D14
DZ1 1 T12702-29 ZENER DIODE,1W,15V,5%,1N4744A
N.A. J1 1 T13160-27 CONNECTOR,PCB,PLUG,12-PIN
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D7
D6
R21
D9
D8
TP1 TP2 R6, R13, R27 3 S19400-4751 RESISTOR,MF,1/4W,4.75K,1%
T1 R7 1 S19400-6811 RESISTOR,MF,1/4W,6.81K,1%
R8 1 S16296-5 TRIMMER,MT,1/2W,10K, 10%,LINEAR
D3
D1
R26
R25
D5
D11 OCI2
DZ1 R9 1 S19400-1001 RESISTOR,MF,1/4W,1.00K,1%
2
C9
D12 R34
R10 1 S19400-4322 RESISTOR,MF,1/4W,43.2K,1%
LED3A 3
R11 1 S19400-3321 RESISTOR,MF,1/4W,3.32K,1%
S1
C11
R41
CV VV
C1
D13
B2 B1 R12, R40 2 S19400-8251 RESISTOR,MF,1/4W,8.25K,1%
Q2 OCI1 R8
R14 1 S19400-4750 RESISTOR,MF,1/4W,475,1%
R44
R28
R45
R49
D14
R32
R33
C14
R19
LED3B
L B3 H R15 1 S19400-9092 RESISTOR,MF,1/4W,90.9K,1%
R14
R35
R15 R16, R19 2 S19400-8252 RESISTOR,MF,1/4W,82.5K,1%
R17
R11
R17, R41 2 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
C17
R7
C3
R5
X2 X3
R43
R42
R46
R48
C2
C7
R16
D10
R31
C18 R20, R26 2 S19400-1000 RESISTOR,MF,1/4W,100,1%
R21 1 S24000-68R0 RESISTOR,WW,3/4W,68,5%
R20
R27
C8
C6
C13
C12
D15
D4
D2
R13
R12
C16
R10
C15
R37
R39
R40
R36
R38
C19
C4
C5
R2
R3
R9
R4
R6
X4 X1 R25 1 S19400-5620 RESISTOR,MF,1/4W,562,1%
.20 R28, R42, R43, R44, R45,
8 S19400-2801 RESISTOR,MF,1/4W,2.80K,1%
0 R46, R48, R49
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}
T1 1 S13000-31 TRANSFORMER,PCB;115V;24V,185MA
N.B. TP1, TP2 2 T13640-14K MOV,150VRMS,13J,7MM
MANUFACTURED AS: X1, X2 2 S15128-4 OP-AMP,QUAD, GEN-PURPOSE,224N
X3 1 S15128-11 IC,COMPARATOR,QUAD,2901N
X4 1 S15128-10 VOLTAGE REF,ADJ, PRECISION,431I
L5394-2K0
NOTES:
}
IDENTIFICATION CODE CAPACITORS = MFD/VOLTS
N.A. DO NOT COAT WITH ENCAPSUATION MATERIAL. RESISTORS = OHMS
N.B. STAND OFF FROM BOARD .25 MAXIMUM. INSPECT BEFORE AND AFTER ENCAPSULATION.
THERE MUST BE NO CRACKS IN THE EPOXY CASE, PARTICULARLY AT THE POINT WHERE MAKE PER E1911
ENCAPSULATE WITH E1844
THE LEADS ENTER THE CASE.
TEST PER E2157-V
N.C. DO NOT EXPOSE TO CLEANING SOLVENT OR VAPORS.
SCHEMATIC REFERENCE: M16966-2K0
FOR PARTS ORDERS:
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L7454-3 ENGINEERING CONTROLLED CHANGE DETAIL: NEW ITEM (USED WITH)* QTY PART NUMBER DESCRIPTION
MANUFACTURER: No 1 1 L7454-B PC BOARD BLANK
5* 1 CF000354 10-32 HEX NUT 3445
8* AS REQ E2387-2 UNINSULATED SOLID TINNED COPPER WIRE,20AWG
10 (SCR1, SCR2)* 2 S20590-1 HEAT SINK,SLIP ON,FOR TO-220
15 1 S14367-1 DIODE AND HEATSINK ASSEMBLY
N.M. 16 1 E3768-4 LABEL .25 x 2.50
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
REFERENCES QTY PART NUMBER DESCRIPTION
B531 1 T13157-14 CONNECTOR,TAB,QC,VERTICAL,1/4,REEL
C1 1 S13490-67 CAPACITOR,ALEL,2,50V,+75/-10%
C2, C4 2 S13490-12 CAPACITOR,ALEL,10,25V,+75/-10%
.25 .03 C3 1 T11577-52K CAPACITOR,CD,.0047/.005,1400V,20%
C5 1 T11577-26 CAPACITOR,PEF,0.1,100V,10%
6.35
C6 1 S13490-31 CAPACITOR,PEF,0.01MF,100V,10%,RADIAL
5.60 C7, C8 2 S13490-102 CAPACITOR,PEMF,.047,100V,10%
3.80 C9 1 S13490-42 CAPACITOR,TAEL,1.0,35V,10%
7.00 +.05
-.02 N.C. .85 0 C11 1 S16668-5 CAPACITOR,CEMO,.022,50V,20%
D1, D9, D10, D11, D12 5 T12199-1 DIODE,AXLDS,1A,400V
N.A.
D2, D3 2 T12199-2 DIODE,AXLDS,1A,1000V
0 DZ1 1 T12702-4 ZENER DIODE,1W,20V,5%,1N4747A
R7 D1
J1 1 T13160-65 CONNECTOR,MOLEX,PCB,6-PIN
.30 .03 J2 1 T13160-5 CONNECTOR,MOLEX,PCB,6-PIN
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C8
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C6 R2
C11
PT1 1 T12737-5 TRANSFORMER,PULSE,3-WINDING,1:1:1
R9
SCR2
R6 D10
DZ1
QU1 R13 .70 Q1, Q2 2 T12704-68 TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
C4
C2
PT1
QU1 1 T12707-4 TRANSISTOR,PUT,TO92,2N6027
R8
R14
R12
R1, R15, R16 3 T12731-8 RESISTOR,METAL FILM,1/2W,10K,2%
R1
C5
R4
R2 1 T12731-34 RESISTOR,METAL FILM,1/2W,22K,2%
R3
R18
C9
D11
Q2 R3 1 T12731-14 RESISTOR,METAL FILM,1/2W,2.7K,2%
SCR1
Q1 R4 1 S19400-1620 RESISTOR,MF,1/4W,162,1%
2.70
C7
D12 R19
D3
R5 1 T14650-1 RESISTOR,WW,15W,1.5K,5%,SQ
R11
R10
D2 R6 1 T12731-6 RESISTOR,METAL FILM,1/2W,33K,2%
R5 R7, R9 2 T12731-17 RESISTOR,METAL FILM,1/2W,4.7K,2%
R15
C1
15
N.B. 3.90 R8 1 T14648-11 RESISTOR,WW,5W,4.7K,5%,SQ
R10 1 T10812-62 TRIMMER,ST,1/2W,500, 10%,LINEAR
R17 J2
R11 1 T10812-77 TRIMMER,ST,1/2W,20K, 10%,LINEAR
R16
R12 1 T12731-2 RESISTOR,METAL FILM,1/2W,27K,2%
D9 R13 1 T12731-31 RESISTOR,METAL FILM,1/2W,47,2%
R14 1 T12731-11 RESISTOR,METAL FILM,1/2W,2.2K,2%
N.J. B531
R17 1 T13165-11 RESISTOR,WW,5W,2.7,5%
TP2
R18 1 S10404-69 RESISTOR,WW,5W,2.5K,5%
R19 1 T12731-22 RESISTOR,METAL FILM,1/2W,3.3K2%
SCR1, SCR2 2 S15161-6 SCR,TO220,12A,400V,2N6397
1 J1
C3
TP1
L7454- 3 TP1, TP2 2 T13640-11K MOV,150VRMS,45J,14MM
TRAV EL
CAPACITORS = MFD/VOLTS
4.50 +.05
-.02 RESISTOR = OHMS
N.B. N.C. N.M.
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REVISION CONTROL
L7454-3B2
NOTES: PART NO. IDENTIFICATION
N.A. SPACE RESISTOR OFF BOARD .16/.10. CODE
N.B. DO NOT COAT WITH ENCAPSULATION MATERIAL. TEST PER E2209-T
N.C. STAND OFF FROM BOARD .25 MAX. INSPECT BEFORE AND AFTER ENCAPSUALTION,
THERE MUST BE NO CRACKS IN THE EPOXY CASE PARTICULARLY AT THE POINT WHERE THE COAT WITH E1844
LEADS ENTER THE CASE. SCHEMATIC REFERENCE: M21076-3B2
N.F. POSITION C3 TOUCHING TP1.
N.H. MOUNT DIODE ASSEMBLY TO BOARD WITH ITEM 5 AT MIDDLE DIODE. MAKE DETAIL
N.J. MAKE CONNECTIONS FROM DIODES TO BOARD WITH ITEM 8. MAINTAIN .20 MIN. MANUFACTURE PER E1911
CLEARANCE BETWEEN JUMPERS AND HEATSINK ASSEMBLY.
N.L. TP1 TO BE POSITIONED IMMEDIATELY PRIOR TO TEST SO THAT .10 MIN. SPACE EXISTS MAKE BLANK FROM S19399
BETWEEN CENTER OF TP1 AND MOLEX. ( 4 BOARDS PER PANEL)
N.M. PRINT "L7454-3" ON ITEM 16 AND APPLY TO ITEM 1 AS SHOWN. PLACE ON TOP OF "L7454-2"
PRINTED ON PC BOARD BLANK. 2 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
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PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL: SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
CLEVELAND
2:1
EQUIPMENT TYPE: LT-7 TRACTOR 1
1 OF ___
PAGE ___
ON 3 PLACE DECIMALS IS .002 in. ( 0.05 mm) DRAWN BY: fivory IF PRINTED DOCUMENT DOCUMENT
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: -
@ A2 SIZE SUBJECT: TRAVEL P.C. BOARD ASSEMBLY NUMBER: REVISION:
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: -
UNITS:
INCH
MATERIAL
DISPOSITION:
NA
APPROVAL
DATE: -
PROJECT
NUMBER: CRM41759
REFERENCE:
L7454-2
L7454-3 A.01
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. individual printed Circuit Board Components are not available from lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
lT-7 TraCTOr