Lincoln Electric Welder IM281 B User Manual

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IM281-B  
March, 1995  
X-Tractor 1G  
For use with equipment having Code Number:  
10205  
10206  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased  
by proper installation ... and  
thoughtful operation on your part.  
DO NOT INSTALL, OPERATE  
OR REPAIR THIS EQUIPMENT  
WITHOUT READING THIS MAN-  
UAL AND THE SAFETY PRE-  
CAUTIONS  
CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
OPERATOR’S MANUAL  
World's Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
Sales and Service through Subsidiaries and Distributors Worldwide  
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100  
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ii  
ii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
4.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
5.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
5.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
4.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
5.c. Cylinders should be located:  
Away from areas where they may be struck or subjected to  
physical damage.  
4.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
5.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
4.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
5.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
5.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
5.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
4.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
4.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
4.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
6.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
4.h. Also see item 7c.  
Mar. ‘93  
X-TRACTOR 1G  
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iii  
iii  
SAFETY  
FOR ENGINE  
ELECTRIC AND MAG-  
NETIC FIELDS  
powered equipment.  
7.a. Turn the engine off before troubleshooting and maintenance  
work unless the maintenance work requires it to be running.  
____________________________________________________  
may be dangerous  
8.a. Electric current flowing through any conductor causes  
localized Electric and Magnetic Fields (EMF). Welding  
current creates EMF fields around welding cables and  
welding machines  
7.b. Operate engines in open, well-ventilated  
areas or vent the engine exhaust fumes  
outdoors.  
8.b. EMF fields may interfere with some pacemakers, and  
welders having a pacemaker should consult their physician  
before welding.  
____________________________________________________  
8.c. Exposure to EMF fields in welding may have other health  
effects which are now not known.  
7.c. Do not add the fuel near an open flame  
welding arc or when the engine is run-  
ning. Stop the engine and allow it to cool  
before refueling to prevent spilled fuel  
from vaporizing on contact with hot  
engine parts and igniting. Do not spill fuel  
when filling tank. If fuel is spilled, wipe it  
up and do not start engine until fumes  
have been eliminated.  
8d. All welders should use the following procedures in order to  
minimize exposure to EMF fields from the welding circuit:  
8.d.1. Route the electrode and work cables together - Secure  
them with tape when possible.  
8.d.2. Never coil the electrode lead around your body.  
____________________________________________________  
8.d.3. Do not place your body between the electrode and  
work cables. If the electrode cable is on your right  
7.d. Keep all equipment safety guards, covers  
and devices in position and in good repair.  
Keep hands, hair, clothing and tools away  
from V-belts, gears, fans and all other  
moving parts when starting, operating or  
repairing equipment.  
side, the work cable should also be on your right side.  
8.d.4. Connect the work cable to the workpiece as close as  
possible to the area being welded.  
8.d.5. Do not work next to welding power source.  
____________________________________________________  
Mar. ‘93  
7.e. In some cases it may be necessary to remove safety  
guards to perform required maintenance. Remove  
guards only when necessary and replace them when the  
maintenance requiring their removal is complete.  
Always use the greatest care when working near moving  
parts.  
7.f. Do not put your hands near the engine fan. Do not  
attempt to override the governor or idler by pushing on  
the throttle control rods while the engine is running.  
7.g. To prevent accidentally starting gasoline engines while  
turning the engine or welding generator during maintenance  
work, disconnect the spark plug wires, distributor cap or  
magneto wire as appropriate.  
___________________________________________________  
7.h. To avoid scalding, do not remove the  
radiator pressure cap when the engine is  
hot.  
X-TRACTOR 1G  
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iv  
iv  
SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A LArc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés possible de  
la zone de travail qu’il est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la peau  
de soudeur et des aides contre le rayonnement de l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar. ‘93  
X-TRACTOR 1G  
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v
v
for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product •••  
as much pride as we have in bringing this product to you!  
Thank You  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be found  
on your machine nameplate.  
Model Name & Number _____________________________________  
Code & Serial Number _____________________________________  
Date of Purchase _____________________________________  
Whenever you request replacement parts for or information on this equipment always supply the information you  
have recorded above.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
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vi  
vi  
TABLE OF CONTENTS  
Page  
Safety .......................................................................................................................................i-iv  
Installation.......................................................................................................................Section A  
Technical Specifications .......................................................................................................A-1  
Safety Precautions ...............................................................................................................A-2  
General Description..............................................................................................................A-2  
Typical Vacuum Motor Output Characteristics......................................................................A-2  
Specific connections for Lincoln equipment.........................................................................A-3  
Operation.........................................................................................................................Section B  
Safety Instructions................................................................................................................B-1  
Operating Instructions ..........................................................................................................B-1  
Maintenance....................................................................................................................Section C  
Safety Precautions...............................................................................................................C-1  
Routine and Periodic Maintenance......................................................................................C-1  
Replacing the Filter.......................................................................................................C-1  
Emptying the Spark Trap...............................................................................................C-1  
Cleaning of Cartridge Type Filters ................................................................................C-1  
Electrical Maintenance.........................................................................................................C-2  
Removal of Housing Assembly.....................................................................................C-2  
Replacement of Brushes ..............................................................................................C-2  
Replacement of Housing Assembly..............................................................................C-3  
Run-In of Brushes.........................................................................................................C-3  
Troubleshooting..............................................................................................................Section D  
Parts Manual & Wiring Diagrams ..................................................................................Appendix  
Parts Pages ..........................................................................................................................2-4  
Wiring Diagrams ......................................................................................................................5  
X-TRACTOR 1G  
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A-1  
A-1  
INSTALLATION  
Technical Specifications- X-tractor 1G  
INPUT  
Sales Spec  
Input Voltage  
Input Current  
K179-4  
120V, 1ø 50/60 Hz  
13.5 A  
K179-5  
220V, 1ø 50/60 Hz  
6.0 A  
VACUUM SPECIFICATIONS  
Air Flow I.C.F.M.  
3
50 C.F.M. (85 m / h) @ 65” WG  
FILTER TYPE  
Paper / Disposable or Manually Cleaned  
OPERATING SOUND LEVEL  
77 dB(A) @ 3.0 Ft.  
AUTOMATIC CONTROL CIRCUIT  
slows motor to 1/2 speed when not welding  
PHYSICAL DIMENSIONS  
HEIGHT  
29.0” (737 mm)  
DIAMETER  
WEIGHT  
13.9” (352 mm)  
45 lbs (20.5 kg)  
X-TRACTOR 1G  
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A-2  
A-2  
INSTALLATION  
Read this entire installation section before you  
motor provides both a drip-proof covering and a mount-  
ing support for the switch and other electrical compo-  
nents. A baffle is built into the cover to prevent re-cir-  
culation of the motor cooling air. The switch turns the  
unit on and lights a pilot light. A relay and resistors per-  
mit the motor to run at half speed when not welding to  
increase motor life. This allows enough air flow to cool  
the gun when not welding and reduces the motor's  
starting current. Operable from either 115 volts AC or  
DC, the relay is energized when the operator pulls the  
gun trigger.  
start installation.  
SAFETY PRECAUTIONS  
Do not attempt to use this equipment until you have  
thoroughly read all installation, operating and mainte-  
nance information supplied with your equipment. They  
include important safety precautions and detailed  
operating and maintenance instructions.  
WARNING  
The filter, made of a paper media, is attached to the  
inside of the canister lid. Filters for these units are sim-  
ilar to those used for large engine air cleaners. The  
inlet pipe is fastened to the bottom of the canister and  
is mounted tangentially to the inside diameter. A baffle  
is mounted above the inlet pipe. When smoke and  
sparks enter the canister, the sparks and heavier  
smoke particles are retained in the bottom of the can-  
ister by a centrifugal action. The centrifugal action and  
baffle prevent sparks from damaging the filter media.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
such as internal wiring.  
Turn the input power off at the fuse  
box or by unplugging the power cable  
before working on this equipment.  
• Have a qualified person install and ser-  
vice this equipment.  
------------------------------------------------------------------------  
A muffler is standard to suppress the noise level of the  
vacuum motor when operating at full speed. A hose  
adapter is provided to allow easy connection of the  
vacuum to any 1-3/4" (45 mm) exhaust hose. Lincoln  
Electric has 1-3/4" hoses for both regular duty (PVC  
flexhose S19947- ) and heavy duty (Reinforced rubber  
S14927-8) applications.  
MOVING PARTS can injure.  
• Do not operate with covers open or fil-  
ter removed.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
Only qualified personnel should install, use or service  
this equipment.  
TYPICAL VACUUM MOTOR OUTPUT  
CHARACTERISTICS  
FIGURE 1  
GENERAL DESCRIPTION  
100  
The arc welding smoke exhaust unit will provide the  
vacuum needed for one X-Tractor or Flux-Cored Fume  
gun, collect visible particles that enter and discharge  
the filtered air. This vacuum does not filter out gases.  
The X-Tractor 1G is particularly valuable for light duty,  
intermittent operation where frequent location changes  
and low equipment costs are of prime importance. The  
unit weighs 45 pounds and contains a reusable filter  
element that collects the particulate matter. The filter  
can be cleaned and reused.  
K179-4 AT 120 VOLTS  
90  
80  
K179-5 AT 240 VOLTS  
70  
K179-5 AT 220 VOLTS  
60  
50  
40  
A control circuit connected to the wire feeder slows the  
motor to 1/2 speed when welding stops. With proper  
maintenance, the average motor life is 2,000 hours.  
30  
20  
10  
0
The smoke exhaust system consists of a vacuum  
motor mounted on a canister with a filter mounted  
inside the canister. See Figure 1 for nominal vacuum  
motor output characteristics. The vacuum motor is  
attached to the lid of the canister. A cover over the  
100  
90  
0
10 20  
30 40  
60  
80  
50  
70  
AIR FLOW IN CFM  
X-TRACTOR 1G  
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A-3  
A-3  
INSTALLATION  
The X-Tractor 1G includes a relay which automatically  
accelerates the vacuum motor to full speed when weld-  
ing starts and slows it to half speed when welding  
stops. This system increases motor life and decreases  
operating noise. The relay requires 115 volt AC or DC  
power. To operate, connect the control cable leads #31  
and #4 to the welding power source contactor control  
circuit. On earlier K179 units, the control leads were  
tagged #1 and #4.  
Plug the K179-4 power cable into 120 volts, 50 or 60  
hertz, single phase grounded 14 amp supply. Connect  
the K179-5 to 220 or 240 volts, 50 or 60 hertz, single  
phase grounded 6 amp supply. (NOTE: No plug is  
supplied with the 220 volt unit.)  
When connecting to Flux-Cored Fume guns, X-Tractor  
guns, or Suction Heads, connect the supplied adapter  
to any 1-3/4" (45 mm) exhaust hose. Lincoln Electric  
has 1-3/4" hoses for both regular duty (PVC flexhose  
S19947- ) and heavy duty (Reinforced rubber S14927-  
8) applications. Then connect the supplied adapter to  
the X-Tractor 1G and connect the hose to the suction  
device.  
Specific connections for Lincoln equip-  
ment are as follows:  
R3S and SAM:  
Connect the leads to #31 and #4 on power source ter-  
minal strip. On earlier machines where a #1 appears  
on the terminal strip, connect the lead #31 to terminal  
#1 and lead #4 to terminal #4.  
DC-400, DC-600, DC-1000, DC-1500 or when a K240  
contactor kit is used:  
Connect the leads to #31 and #4 at power source or at  
K240 contactor kit.  
SAF-600 or SA-800:  
Connect lead #31 to #1 and #4 to #4 on the power  
source terminal strip.  
When using a DC-250, CV or CVI type power source  
(or when the power source is in an inaccessible  
location), the control leads must be connected to the  
wire feeder as follows:  
LN-6:  
Connect lead #31 to #1 and #4 to #4 on the terminal  
strip inside the LN-6 control box at the wire feed unit.  
LN-7, LN-8 & LN-9:  
Connect the leads to the auxiliary equipment contacts  
#7 and #32A inside the wire feeder control box. To do  
this, change the connectors on the end of the X-Tractor  
leads to the lugs taped to the ends of the leads. Refer  
to appropriate IM manual for terminal location and lead  
routing information. Either lead can go to either con-  
tact terminal.  
X-TRACTOR 1G  
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B-1  
B-1  
OPERATION  
Read and understand this entire section before operat-  
ing your X-Tractor 1G.  
Only qualified personnel should operate this equip-  
ment.  
ADDITIONAL SAFETY PRECAUTIONS  
SAFETY INSTRUCTIONS  
Always operate this equipment with the filter installed  
and covers in place as these provide maximum protec-  
tion from moving parts and insure proper vacuum oper-  
ation and cooling air flow.  
Do not attempt to use this equipment until you have  
thoroughly read all operating and maintenance man-  
uals supplied with your equipment and any related  
welding machine it will be used with. They include  
important safety precautions, operating and mainte-  
nance instructions and parts lists.  
OPERATING INSTRUCTIONS  
Turn the power switch on and the unit is ready for weld-  
ing. When operator pulls the gun trigger, the vacuum  
motor will speed up to provide proper vacuum for  
smoke removal.  
WARNING  
ELECTRIC SHOCK can kill.  
•Do not touch electrically live parts such  
as output terminals or internal wiring.  
NOTE: New filters will leak smoke for the first few min-  
utes of operation.  
•Insulate yourself from the work and  
ground.  
To insure proper smoke removal, the filter (M12284-1)  
typically requires replacement with a new or cleaned  
element after welding with 75 to 150 pounds of  
Innershield® electrode depending on the type of elec-  
trode used and the efficiency of smoke pickup. (When  
using the MIG welding process, the amount of elec-  
trode between cleanings can be substantially higher.)  
•Always wear dry insulating gloves.  
------------------------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
To replace the filter, turn the unit off, disconnect the  
power cord and remove the clamping ring from the top.  
Lift the top and the filter from the canister. Remove the  
wing nut on the bottom of the filter and install a new or  
cleaned element. Make certain that the large flat  
washer is placed under the wing nut.  
•Keep flammable material away.  
•Do not weld upon containers which  
have held combustibles.  
------------------------------------------------------------------------  
ARC RAYS can burn.  
Used filters can be cleaned and reused. See the  
Maintenance Section for cleaning instructions.  
•Wear eye, ear and body protection.  
Clean accumulated material from bottom spark trap  
every 300 to 400 pounds of electrode.  
------------------------------------------------------------------------  
FUMES AND GASES  
can be dangerous.  
• Although the removal of the particu-  
late matter from welding smoke may  
reduce the ventilation requirement,  
concentrations of the clear exhausted  
fumes and gases may still be haz-  
ardous to health. Avoid breathing  
concentrations of these fumes and  
gases. Use adequate ventilation  
when welding. See ANSI Z49.1,  
"Safety in Welding and Cutting", pub-  
lished by the American Welding  
Society.  
------------------------------------------------------------------------  
X-TRACTOR 1G  
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C-1  
C-1  
MAINTENANCE  
Emptying the Spark Trap  
SAFETY PRECAUTIONS  
WARNING  
The spark trap should be checked each time a filter is  
changed. Clean accumulated material from bottom  
spark trap every 300 to 400 pounds of electrode.  
•Have a qualified technician do the maintenance  
and troubleshooting work.  
•Turn the equipment off and disconnect from main  
power before working on the machine.  
Cleaning of Cartridge Type Filters  
•Remove covers only when necessary and replace  
them when the maintenance requiring their  
removal is complete.  
WARNING  
• The dust and particulate matter collected by these fil-  
ters can be dangerous to your health. Take neces-  
sary precautions so you and your fellow workers do  
not breathe the dust and particulate matter. Wear a  
suitable respirator and, when cleaning filters, do it  
under a force-ventilated hood such as a welding or  
paint hood.  
•Always use the greatest care when working near  
moving parts.  
------------------------------------------------------------------------  
Read the Safety Precautions throughout this manual  
and the welder instruction manual before working on  
this machine.  
ª Properly dispose of collected material.  
------------------------------------------------------------------------  
Clean per the following instructions:  
Keep all equipment covers and devices in position and  
in good repair. Keep hands, hair, clothing and tools  
away from fans and all other moving parts when oper-  
ating or repairing this equipment.  
1.Gently brush the collected material off the outside of  
the filter.  
2.Loosen dust by successively dropping filter approxi-  
mately one inch on a hard surface while rotating 10-  
20° after each drop. Do not drop filter on its corner.  
ROUTINE AND PERIODIC  
MAINTENANCE  
Replacing the Filter  
To insure proper smoke removal, the filter (M12284-1)  
typically requires replacement with a new or cleaned  
element after welding with 75 to 150 pounds of  
Innershield® electrode depending on the type of elec-  
trode used and the efficiency of smoke pickup. (When  
using the MIG welding process, the amount of elec-  
trode between cleanings can be substantially higher.)  
FIGURE 2  
ROTATE AFTER  
EACH DROP  
APPROX. 1.00"  
DROP DISTANCE  
To replace the filter:  
a)Turn the unit off.  
b)Disconnect the power cord.  
c)Remove the clamping ring from the top.  
d)Lift the top and the filter from the canister.  
e)Remove the wing nut on the bottom of the fil-  
ter and install a new or cleaned element.  
Make certain that the large flat washer is  
placed under the wing nut.  
3.Enclose filter in a plastic bag several times larger  
than the size of the filter. Secure the bag to the gas-  
ket end of the filter. (A rubber band is effective.)  
Blow air through filter using compressed air. Air sup-  
ply must be 80-100 psi and the nozzle should be kept  
at least one inch away from the filter element.  
f)Reassemble in reverse order.  
NOTE: Used filters can be cleaned and reused.  
NOTE: New filters will leak smoke for the first few min-  
utes of operation.  
X-TRACTOR 1G  
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C-2  
C-2  
MAINTENANCE  
a. Tools Needed: 4" flat blade screwdriver  
FIGURE 3  
3/8" open end or box wrench  
1/4" socket or nut driver/  
1/2" socket  
80 - 100 PSI  
AIR SUPPLY  
*
GASKET END  
OF AIR FILTER  
5/16" socket or nut driver  
4" socket extension and ratchet.  
RUBBER BAND  
b. Removal of Housing Assembly - See Figure 4.  
1.Turn off the input power being supplied to the  
X-Tractor unit and the arc welding power  
source being used.  
PLASTIC  
BAG  
2.Remove three 5/16"-18 x 5/8" bolts, lock-  
washers and plain washer that hold control  
housing to canister cover using a " socket  
and 4" extension. Do not remove the acorn  
nuts on the top cover.  
*If air supply is limited to 30 psi, use a booster air gun  
that increases dynamic pressure and still retains a 30  
psi static pressure such as Guardair Booster Air Gun,  
Model 57530XB made by Union Engineering  
Corporation.  
3.Lift housing approximately 6" and tip to one  
side.  
4.Remove motor leads from terminal strip  
using a 4" flat blade screwdriver.  
4.After Step 3, repeat the procedure in Step 2 for sev-  
eral minutes to remove material loosened by the air.  
5.Use a 3/8" wrench to remove the outer 10-24  
nut from the grounding screw. Remove the  
green motor lead from grounding screw.  
5.All the material removed should be carefully put into  
the plastic bag used in Step 3 for disposal.  
6.Remove the housing from unit.  
With reasonable care in handling, these filters can eas-  
ily be reused five or six times. The limiting factor in  
their service life is the point where the element is frac-  
tured or torn, permitting the continuous passage of  
smoke. Using a fractured or torn filter may seriously  
shorten the life of the vacuum unit.  
c. Replacement of Brushes  
1.To insure optimum commutation on  
reassembly, mark the relative location of the  
screw heads in the slots and remove the two  
#10-24 x 2 screws from the top end bracket  
of the vacuum motor using a 5/16" socket or  
nut driver.  
Electrical Maintenance  
WARNING  
Have a qualified electrician do the maintenance and  
troubleshooting work. Turn OFF the arc welding power  
source and disconnect control leads #31 and #4 at  
power source or wire feeder. Remove the power cable  
plug from its receptacle or turn the input power off  
using the disconnect switch at the fuse box.  
------------------------------------------------------------------------  
Check motor brushes after 1,000 hours of operation or  
about every six months. Brushes worn to 1/4 inch long  
should be replaced. Brush part number is S14688-D.  
Two brushes are required per motor. Instructions for  
checking and/or replacement of the brushes are as fol-  
lows:  
FIGURE 4  
TOP END  
CONTROL  
HOUSING  
BRACKET  
#10-24 HEX  
HEAD SCREW  
MOTOR  
COVER  
5/16-18x5/8" BOLT,  
LOCKWASHER  
& PLAIN WASHER  
BRUSH  
HOLDER  
CANISTER  
COVER  
X-TRACTOR 1G  
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C-3  
C-3  
MAINTENANCE  
2.Lift off the top end bracket from the motor.  
Be careful not to lose the bearing pre-load  
spring washer. Lift the cylindrical motor  
cover up from the motor, slide back on the  
leads and tilt away from motor.  
10.Place motor cover over motor. Make sure  
the bearing spring washer is on top of the  
armature bearing and positioned to fit into  
bearing seat in the top end bracket.  
11.Position the top end bracket so the bolt  
slots are directly over the threaded holes in  
motor frame. Place the #10-24 x 2.0"  
screws through the slots and install loosely  
using a 5/16" socket or nut driver. Rotate  
the top end bracket to align heads of the  
screws with the marks at the slots made in  
Step c.1 and tighten.  
3.Locate brushes on opposite sides of the  
commutator. Using a 1/4” socket or nut dri-  
ver, remove two #8-32 hex head screws from  
each brush holder retaining bracket and  
remove brackets.  
4.Move brush holder assemblies away from  
commutator in order to remove coil leads  
from brush holders.  
d. Replacement of Housing Assembly  
FIGURE 5  
Attach motor leads and install housing assem-  
bly in the reverse order of Step b.  
COIL  
LEAD  
BRUSH  
HOLDER  
BRUSHES  
e. Run-in of Brushes  
B
TOP VIEW  
A
After replacing brushes, run smoke exhaust  
unit on low idle for 30 minutes. Unit is on low  
idle when power cable is energized, power  
switch is on, and control (#31 and #4) cable is  
not connected.  
5.Place a screwdriver in area A to pry lead  
from brush holder assembly. Do not pry or  
pull on bare section of lead denoted by B in  
Figure 5.  
See S17238 included with replacement motor for  
instructions for complete vacuum motor replacement.  
6.To install new brushes, push tab on each coil  
lead into the slot on either side of brush hold-  
er. Do not bend the bare section of lead (B).  
7.Place each brush assembly in position on  
bottom motor housing with coil lead on top.  
FIGURE 6  
C
BOTTOM VIEW  
8.The brush assembly will be properly posi-  
tioned when the raised round locater in the  
brush area of the bottom housing fits into the  
indented section on the brush assembly that  
is marked "C" in Figure 6. The brass portion  
of the brush holder will be approximately 1/8"  
from the commutator.  
9.With the brush assembly in position, place  
brush hold down bracket over each brush  
holder. Start the four #8-32 hex head screws  
by hand to avoid cross-threading. Tighten  
screws with a 1/4” socket or nut driver.  
X-TRACTOR 1G  
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D-1  
D-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
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  
help you locate and repair possible machine  
malfunctions. Simply follow the three-step  
procedure listed below.  
Step 3. RECOMMENDED COURSE OF  
ACTION  
If you have exhausted all of the items in step  
2. Contact your Local Lincoln Authorized  
Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes pos-  
sible symptoms that the machine may exhib-  
it. Find the listing that best describes the  
symptom that the machine is exhibiting.  
Step 2. PERFORM EXTERNAL TESTS.  
The second column labeled “POSSIBLE  
AREAS OF MISADJUSTMENT(S)” lists the  
obvious external possibilities that may con-  
tribute to the machine symptom. Perform  
these tests/checks in the order listed. In  
general, these tests can be conducted with-  
out removing the case wrap-around cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
X-TRACTOR 1G  
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3-10-95  
D-2  
D-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
PROBLEMS  
1.Be sure all tubing connections are  
tight and there are no punctures in  
hose.  
No Smoke Pickup  
2. Control relay not connected.  
Control leads #31 and #4 must be  
energized for full power.  
3.Filter needs cleaning.  
4.Plugged or damaged welding gun.  
Refer to appropriate IM manual for  
gun maintenance.  
Contact your Local Lincoln Authorized  
Field Service Facility for technical  
troubleshooting assistance.  
Motor won’t operate in any mode.  
1.Verify power to the unit.  
2.Check motor brushes and replace  
if necessary.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
X-TRACTOR 1G  
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1
1
PARTS  
X-TRACTOR 1G  
PARTS MANUAL  
Codes: 10205 & 10206  
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the  
Lincoln Electric Parts List.  
X-TRACTOR 1G  
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2
2
PARTS  
P-147-E  
MAGNUM X-TRACTOR CONTROL CASE ASSEMBLY  
ꢂꢁ  
ꢂꢈ  
ꢁꢃ  
ꢂꢅ  
ꢁꢈ  
ꢁꢉ  
ꢂꢃ  
ꢁꢆ  
ꢁꢄ  
ꢁꢋꢋꢁꢅ  
ꢂꢆ  
ꢁꢅ  
ꢂꢄ  
ꢁꢂ  
ꢁꢁ  
ꢁꢂꢅꢇ  
ꢁꢂꢅꢇ  
L6694-3  
2-19-93E  
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the  
Lincoln Electric Parts List.  
X-TRACTOR 1G  
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3
3
PARTS  
Part  
No.  
No.  
Req’d.  
P-147-E.1  
MAGNUM X-TRACTOR CONTROL CASE  
ASSEMBLY  
Item Description  
1
2
3
Shell Assembly  
Support Bracket  
Lead Grommet  
Cable Asbly. (115V)  
Cable Asbly. (220/240V)  
Pilot Light and Terminal  
Asbly. (115V)  
M14360-1  
S17227-1  
T9274-3  
S14687  
1
3
1
1
1
1
Part  
No.  
No.  
Req’d.  
Item Description  
Lock Washer  
S14687-1  
T13429  
T9860-3  
2
3
1
1
1
4
4
Plain Washer  
S9262-121  
T13260-4  
T13470  
28  
29  
29  
Decal (Ground)  
Decal (Warning) (115V)  
Decal (Warning)  
(220/240V)  
Pilot Light and Terminal  
Asbly. (220/240V)  
Toggle Switch  
Relay  
T13429-1  
1
T13086-20  
5
6
7
S9264  
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
3
1
4
3
3
1
1
1
1
1
1
2
1
6
2
1
2
S14705  
31  
Fastener Button  
T14659-1  
1
Relay Cable  
S17226  
Lead Grommet  
Resistor  
T9274-2  
S10404-7A  
T9781-20  
S17304  
8
Resistor Mounting Stud  
Resistor Mounting Bracket  
Baffle  
9
M12523-3  
T12380-2  
S13323-5  
T13188  
10  
11  
Bushing  
Terminal Strip  
Terminal Strip Insulation  
Insulation  
12  
13  
T13441  
Thyractor Diode  
Diode Clamp  
T13640-14  
T12563-4  
T12986  
14  
16  
17  
18  
19  
Rectifier  
Hex Head Screw  
Baffle Assembly  
Self Tapping Screw  
Lock Washer  
5/16-18x5.75  
S17232  
S8025-4  
E106A-14  
5/16-18  
Hex Jam Nut  
20  
21  
Cover Assembly  
Lifting Handle  
M12286-2  
M15446  
Plain Washer  
S9262-121  
T9860-3  
S9225-36  
T9695-1  
#10-24  
Lock Washer  
23  
24  
Thread Cutting Screw  
Lock Washer  
Hex Nut  
Nameplate  
S20312-1  
T14659-1  
S8025-73  
S11893-2  
T13167-1  
Fastener Button  
Self Tapping Screw  
Lincoln Welder Decal  
Acorn Nut  
25  
27  
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the  
Lincoln Electric Parts List.  
X-TRACTOR 1G  
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4
4
PARTS  
P-147-D  
MAGNUM X-TRACTOR GENERAL ASSEMBLY  
ꢁꢂ  
ꢁꢅ  
ꢁꢁ  
L6694-3  
9-4-92D  
Part  
No.  
No.  
Req’d.  
Part  
No.  
No.  
Req’d.  
Item Description  
Item Description  
1
2
3
Canister and Tube Asbly.  
S14801-1  
M12285-1  
M12284-1  
T9078-10  
L5066-C  
1
1
1
1
1
1
1
1
1
2
3
6
3
3
8
9
Control Case Asbly.  
See P147-E  
5/16-18x.625  
S9262-30  
E106A-14  
S11893-2  
M16530  
1
3
3
3
1
1
1
1
1
1
Canister Cover  
Air Filter  
Hex Head Screw  
Plain Washer  
Lock Washer  
Lincoln Welder Decal  
Decal (X-Tractor)  
Hex Nut  
Thumb Screw  
Gasket  
4
10  
10  
11  
12  
Locking Ring  
Rubber Washer  
Vacuum Motor (115V)  
Vacuum Motor (220/240V)  
Motor Brush  
L5066-F  
5
6
6
T11135-12  
S14968-2  
S14968-3  
S14688-D  
5/16-18x1.75  
E106A-14  
S9262-30  
5/16-18  
#10-24  
Muffler  
M12253  
Clamp  
S10888-21  
S20591-6  
Hose Adapter  
7
Hex Head Screw  
Lock Washer  
Plain Washer  
Hex Nut  
3-10-95  
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the  
Lincoln Electric Parts List.  
X-TRACTOR 1G  
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5
5
DIAGRAMS  
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ꢑꢒꢖ& ꢘ" ꢑꢀ%ꢕꢒꢙꢏ  
ꢂꢎꢂꢊꢎꢆ  
#ꢁꢄꢈꢂꢂ  
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X-TRACTOR 1G  
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Do not touch electrically live parts or Keep flammable materials away.  
Wear eye, ear and body protection.  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
WARNING  
Spanish  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à lécart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO  
BE USED AND FOLLOW YOUR EMPLOYERS SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant lentre- Nopérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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