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Lincoln Electric LT-7 User Manual

Lincoln Electric LT-7
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SERVICE MANUAL
SVM198-A | Issue D ate 10-Jul
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
7429 thru 11358
LT-7 LIGHTWEIGHT TRACTOR
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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.
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Lincoln Electric LT-7 Specifications

General IconGeneral
BrandLincoln Electric
ModelLT-7
CategoryTractor
LanguageEnglish

Summary

Safety

California Proposition 65 Warnings

Specific warnings regarding California Proposition 65.

Engine Safety Precautions

Safety guidelines for operating equipment with engines.

Electric and Magnetic Field Safety

Warnings and precautions regarding Electric and Magnetic Fields (EMF).

Electric Shock Hazards

Critical safety information about the dangers of electric shock.

Arc Ray Hazards

Safety measures to protect against arc rays and sparks.

Fume and Gas Hazards

Precautions for handling welding fumes and gases.

Fire and Explosion Hazards

Safety measures to prevent fires and explosions from welding sparks.

Cylinder Safety

Precautions for handling compressed gas cylinders.

Electrically Powered Equipment Safety

Safety guidelines for electrically powered equipment.

Electromagnetic Compatibility (EMC)

Information on electromagnetic compatibility and interference.

Methods of Reducing Emissions

Techniques for minimizing electromagnetic emissions.

Welding Equipment Maintenance

Guidelines for routine maintenance of welding equipment.

Product Overview

Specifications

Technical specifications of the LT-7 Tractor.

Product Summary

An overview of the LT-7 Tractor's features and capabilities.

General Physical Description

Physical characteristics and build of the LT-7 Tractor.

Features

Key attributes and functionalities of the LT-7 Tractor.

Recommended Processes and Equipment

Guidance on suitable welding processes and required equipment.

Recommended Processes

Specific welding processes recommended for the LT-7 Tractor.

Process Limitations

Constraints and limitations on welding processes for the LT-7 Tractor.

Recommended Power Sources

Compatible power sources for the LT-7 Tractor.

Required Equipment

Necessary equipment for operating the LT-7 Tractor.

Cables

Details and part numbers for various cables.

Contact Nozzle Assemblies

Information on different contact nozzle assemblies.

Recommended General Options

Recommended optional accessories for the LT-7 Tractor.

Initial Set Up

LT-7 Tractor Nomenclature

Identification of LT-7 Tractor parts and components.

Tractor Drive Components

Key components related to the tractor's movement and steering.

Wire Feed and Control Components

Identification of components involved in wire feeding and control.

Control Box

Overview and functions of the tractor's control box.

Front Guidance Assembly

Components related to the front guidance system.

Wire Feed Head Components

Components of the wire feed head assembly.

Flux Hopper Assembly

Description of the flux hopper assembly.

Head Mounting and Adjusting

Procedures for mounting and adjusting the welding head.

Assembly

General Information

General information pertaining to the assembly process.

Tools Required

List of necessary tools for assembly and setup.

K231-1 Contact Nozzle

Installation and operation of the K231-1 contact nozzle.

K148 Contact Nozzle

Details on K148 contact nozzle usage, installation, and maintenance.

K148 Installation

Step-by-step instructions for installing the K148 nozzle.

K148 Contact Tip Wear and Replacement

Guidance on contact tip wear and replacement for K148 nozzle.

K149 Linc-Fill™ Long Stick-Out Extension

Installation of the K149 Linc-Fill extension for long stick-out.

Water Cooling Attachment

Information on the water cooling attachment for tip life.

Mechanical Setup for Various Types of Welds

Procedures for mechanically setting up the tractor for different weld types.

Set Up for Butt Welds

Instructions for setting up the tractor for butt welds.

Right or Left Butt Welds and Short or Long Stickout

Setup procedures for specific butt weld configurations.

Steering Methods

Various methods for steering and tracking the tractor.

The Self-Steering Method

Guidance on using the self-steering method.

Pointer Assembly

Using the pointer assembly for weld alignment.

Optional K230 Butt Guide

Installation and use of the K230 Butt Guide.

Channel Tracking

Setup for tracking using channels.

Bar Tracking

Setup for tracking using bars.

Set Up for Horizontal Fillet Welds

Instructions for setting up the tractor for horizontal fillet welds.

Front Guidance Assembly

Setup of the front guidance assembly for horizontal fillets.

Head Mounting

Procedures for mounting and adjusting the welding head for horizontal fillets.

The K232 Fillet-Lap Guide Kit

Information on the K232 Fillet-Lap Guide Kit.

K232 Installation

Step-by-step installation of the K232 Kit.

Alignment in the Joint

Procedures for aligning the tractor in the weld joint.

Set Up for Lap Welds

Instructions for setting up the tractor for lap welds.

Set Up for Lap Welding

Procedures for welding lap joints.

Set Up for Flat Fillet Welds

Instructions for setting up the tractor for flat fillet welds.

The K229 Flat Fillet Kit

Information on the K229 Flat Fillet Kit.

K229 Installation

Step-by-step installation of the K229 Kit.

Front Guidance Assembly

Setup of the front guidance assembly for flat fillets.

Rear Support Wheel

Installation of the rear support wheel.

Reel and Control Box Mounting

Mounting the reel and control box for Twinarc modifications.

Head Mounting

Mounting the head for flat fillet welds.

Alignment in the Joint

Aligning the tractor in the joint for flat fillets.

K395 Track Model LT-7

Overview of the K395 Track Model LT-7.

Track Model Features

Key features of the track model LT-7.

K395 Configuration

Steps to configure the K395 track model.

On-Track Setup Configuration

Procedures for setting up the tractor on-track.

Rear Wheel Configuration

Steps for configuring the rear wheels.

Front Frame Configuration

Steps for configuring the front frame.

K395 Configuration (cont.)

Continuation of K395 track model configuration.

Off-Track Setup Configuration

Procedures for setting up the tractor off-track.

K400 LT-7 Track Conversion Kit

Information on the K400 track conversion kit.

K400 Conversion Kit Parts

List of parts included in the K400 conversion kit.

K396 Track Sections

Information about K396 track sections.

K277-1 and K277-2 Tiny Twinarc® Kits for Submerged Arc Welding

Details on Tiny Twinarc kits for submerged arc welding.

K277 Tiny Twinarc® Parts

List of parts included in the K277 Tiny Twinarc kits.

LT-7 Modification for Twinarc® Welding

Procedures for modifying the LT-7 for Twinarc welding.

A. Wire Feed Head Modifications for Tiny Twinarc®

Specific modifications to the wire feed head for Twinarc.

1. Wire Straightener Modifications

Steps for modifying the wire straightener.

1. Frame Conversion

Steps for frame conversion for butt and horizontal fillet welds.

2. Butt Welds (Tiny Twinarc)

Specific modifications for butt welds using Twinarc.

3. Horizontal Fillet Welds (Tiny Twinarc)

Specific modifications for horizontal fillet welds using Twinarc.

4. Horizontal Lap Welds (Tiny Twinarc)

Specific modifications for horizontal lap welds using Twinarc.

C. Frame Modifications for Twinarc® 45° Flat Fillets

Frame modifications for 45° flat fillet welds with Twinarc.

K280 Vertical Head Lift Adjuster

Information on the K280 Vertical Head Lift Adjuster.

Electrical Installation

Electrical Connections

Steps for making electrical connections to the LT-7 Tractor.

Recommended Copper Cable Sizes for Arc Welding

Guidelines for selecting appropriate copper cable sizes.

Loading a Coil on to a Reel

Procedures for loading welding wire coils onto the reel.

Operation

Safety Precautions

Essential safety measures before operating the tractor.

Mechanical Hazards Can Cause Serious Injury

Warnings about mechanical hazards during operation.

Electrode Potential

Understanding parts at electrode potential and maintaining clearance.

General Operating Guidelines

Basic guidelines for operating the LT-7 Tractor safely.

Control Box

Overview of the LT-7 control box functions and controls.

General Information

General information regarding operation settings.

Constant Current vs. Constant Voltage

Explanation of Constant Current and Constant Voltage modes.

Constant Current

Details on operating in Constant Current mode.

Constant Voltage

Details on operating in Constant Voltage mode.

Mode Selection

Procedure for selecting between CC and CV modes.

Polarity Selection

Instructions for selecting weld polarity (Positive/Negative).

Making a Weld

Step-by-step guide to performing a weld with the LT-7 Tractor.

Theory of Operation

General Description

A general description of the LT-7 Tractor's capabilities.

Input Power Circuits

Explanation of the LT-7's input power circuitry.

Control and Logic Circuits

Explanation of the tractor's control and logic systems.

Travel Circuit

Technical explanation of the LT-7's travel circuit.

Variable Voltage Circuit

Technical explanation of the variable voltage circuit.

SCR Operation

Explanation of how Silicon-Controlled Rectifier (SCR) circuitry controls speed.

Maintenance

Routine Maintenance

General guidelines for routine maintenance.

Safety Precautions

Safety measures to be taken during maintenance.

Wire Feed Head

Maintenance procedures for the wire feed head assembly.

Wire Drive Motor And Gear Box

Maintenance for the wire drive motor and gearbox.

Drive Rolls and Guide Tubes

Inspection and maintenance of drive rolls and guide tubes.

Wire Straightener

Inspection and maintenance of the wire straightener.

Contact Nozzle Assembly

Maintenance of the contact nozzle assembly.

Wire Reel Mounting – 50 and 60 Pound Coils

Procedures for mounting wire reels to prolong shaft life.

Control Box

Basic maintenance for the control box.

Travel Components

Maintenance for the tractor's drive motor gearbox and clutch.

Circuit Protection

Information on circuit protection features and resetting breakers.

Grounding Lead Protector

Explanation and reset procedure for the Grounding Lead Protector.

Troubleshooting and Repair

How to Use Troubleshooting Guide

Instructions on how to effectively use the troubleshooting guide.

Troubleshooting Guide

A comprehensive guide to diagnosing and resolving machine problems.

PC Board Troubleshooting Procedures

Procedures for troubleshooting PC board related issues.

PC Board Status Lights

Understanding the meaning of PC board status indicator lights.

Test Procedures

Specific procedures for testing various components.

Wire Drive Motor Test

Procedure to test the functionality of the wire drive motor.

Travel Motor Test

Procedure to test the functionality of the travel motor.

Wire Drive Motor Removal and Replacement

Steps for removing and replacing the wire drive motor.

Travel Motor Removal and Replacement

Steps for removing and replacing the travel motor.

Travel Circuit Calibration

Procedure for calibrating the travel circuit.

Retest After Repair

Steps to retest the machine after repairs.

Output Problems

Common output issues and their troubleshooting steps.

Electrical Diagrams

Wiring Diagram - Below Code 9100 (L5879)

Wiring diagram for models below Code 9100.

Wiring Diagram - Above Code 9100 (L7460)

Wiring diagram for models above Code 9100.

Connection Diagram - Below Code 9100 (M13514)

Connection diagram for models below Code 9100.

Connection Diagram - Above Code 9100 (M15342)

Connection diagram for models above Code 9100.

Schematic – Complete Machine - Below Code 9100 (G1452)

Complete machine schematic for models below Code 9100.

Schematic – Complete Machine - Above Code 9100 (G1790)

Complete machine schematic for models above Code 9100.

PC Board Assembly – Control Board - L6959-2

Diagram of the control board assembly.

PC Board Assembly – Logic Board - L5927-2

Diagram of the logic board assembly.

Schematic - Variable Voltage Board - M16966-2K0

Schematic of the variable voltage board.

PC Board Assembly – Variable Voltage Board - L5394-2

Diagram of the variable voltage board assembly.

PC Board Assembly – Travel Board - L7454-3

Diagram of the travel board assembly.

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