Lincoln Electric X-TRACTOR 3A Service Manual
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Lincoln Electric X-TRACTOR 3A Service Manual

Lincoln Electric X-TRACTOR 3A Service Manual

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X-TRACTOR
®
3A
For use with machines having Code Numbers:
K3965-1 & K3965-2
SERVICE MANUAL
SVM244-A
| Issue D ate 14-Jan
© Lincoln Global, Inc. All Rights Reserved.
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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Summary of Contents for Lincoln Electric X-TRACTOR 3A

  • Page 1 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. X-TRACTOR ® For use with machines having Code Numbers: K3965-1 & K3965-2 SERVICE MANUAL SVM244-A | Issue D ate 14-Jan ©...
  • Page 2 Service and repair should be performed by only exhaust at the arc, or both, to keep Lincoln Electric Factory Trained Personnel. Unauthorized the fumes and gases from your breathing zone and the general area. repairs performed on this equipment may result in danger...
  • Page 3 American Welding Society, P.O. Box 351040, Miami, Florida 33135 MAGNETIC FIELDS MAY or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 X-TRACTOR ® 3A SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover electrically “hot” when the welder is on. Do plates to protect your eyes from sparks and the rays of the arc not touch these “hot”...
  • Page 5 X-TRACTOR ® 3A SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. and properly operating regulators designed for If this is not possible, cover them to prevent the gas and pressure used.
  • Page 6 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding equipment, in metallic conduit or equivalent. Shielding should be Equipment. It is for use with other Lincoln Electric equipment. It is electrically continuous throughout its length. The shielding should be designed for industrial and professional use.
  • Page 7 X-TRACTOR ® 3A SAFETY Ventilation As a rule of thumb, for many mild steel electrode, if the air is visibly clear and you are comfortable, then the ventilation is generally There are many methods which can be selected by the user to adequate for your work.
  • Page 8 TLV and PEL values are as of April 2006. Always check Material Know Act of 1986 and of 40CFR 370 and 372. Safety Data Sheet (MSDS) with product or on the Lincoln Electric website at http://www.lincolnelectric.com (b) The PEL for chromium (VI) is .005 milligrams per cubic meter as an 8 hour time weighted average.
  • Page 9 X-TRACTOR ® 3A NOTES viii...
  • Page 10 X-TRACTOR ® 3A TABLE OF CONTENTS RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ....................................ii-viii Installation, Operation, Accessories, Maintenance .................... See IM10159 Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F Electrical Diagrams ..............................Section G...
  • Page 11 X-TRACTOR ® 3A THEORY OF OPERATION TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory Of Operation ......................Section E Input ..............E-2 Motor Control Circuitry .
  • Page 12 Two phases of the three phase input is also applied through a fuse to the step down control transformer. The 24 volt secondary supplies power to the control circuitry and to the X-Tractor 3A machine. NOTE: Unshaded areas of Block Logic...
  • Page 13 X-TRACTOR ® 3A THEORY OF OPERATION Figure E.3 - Motor control circuitry K1 MOTOR RELAY 3 PHASE 3 PHASE MOTOR 3Φ CLEANING SWITCH TIMER T1 TIMER CLEANING DIGITAL CONTACTS SOLENOID TERMINAL TIMER AUXILIARY N.O. VALVE STRIP ACTIVATION CONTACTS SIGNAL N.O. N.O.
  • Page 14 X-TRACTOR ® 3A THEORY OF OPERATION Figure E.4 - Cleaning circuitry K1 MOTOR RELAY 3 PHASE 3 PHASE MOTOR 3Φ CLEANING SWITCH TIMER T1 TIMER CLEANING DIGITAL CONTACTS SOLENOID TERMINAL TIMER AUXILIARY N.O. VALVE STRIP ACTIVATION CONTACTS SIGNAL N.O. N.O. F1 AUXILIARY T2 CONTACTS CONTACTS...

  • Page 15: Table Of Contents

    X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting And Repair ....................Section F How to Use Troubleshooting Guide ..........F-2 Troubleshooting Guide .

  • Page 16: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only 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.

  • Page 17: Troubleshooting Guide

    (TR1) secondary. See the Wiring Diagram. CAUTION 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 18 4. There may be leakage in the system. CAUTION 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 19: Case Cover Removal And Replacement Procedure

    CASE COVER REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 20 MOUNTING SCREWS (TWO ON EACH SIDE) REMOVAL PROCEDURE 1. Remove input power to the X-Tractor 3A. 2. Using a 1/4” nutdriver, remove the four screws (two on each side) securing the case cover. See Figure F.1. NOTE: For fast access to internal components only remove the two front screws (one on each side) from the case cover.
  • Page 21 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.2 – Case cover tilted REPLACEMENT PROCEDURE 1. Carefully position cover on to machine. NOTE: Skip step two if cover was simply tilted for internal component access.
  • Page 22 X-TRACTOR ® 3A NOTES...

  • Page 23: Control Transformer (Tr1) Resistance Test (460V Machine

    (460V MACHINE) 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.
  • Page 24 6. Check the resistance of the 24 Volt secondary winding in the control transformer. Normal resistance is approximately 0.2 ohms. This resistance may vary if testing an 230 Volt X-Tractor 3A machine. 7. Check the resistance of the 460 Volt primary winding in the control transformer.
  • Page 25 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR CONTROL TRANSFORMER (TR1) RESISTANCE TEST (460V MACHINE) (continued) Figure F.4 – Primary and secondary locations SECONDARY LEADS LEAD 24 LEAD 0 SEC.: – MAX. LOAD 3.75A PRI.: – 460V – 480V – 500V 47-63HZ LEAD 0 LEAD 460 PRIMARY LEADS...
  • Page 26 X-TRACTOR ® 3A NOTES F-12...

  • Page 27: M1 Three-Phase Fan Resistance Test (460V Machine

    (460V MACHINE) 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.
  • Page 28 M1 fan. Normal resistance between phases should be approximately 4.5 ohms. This value may be different if testing the fan in an 230 Volt X-Tractor 3A machine. 6. Also check the resistance between the three input leads and ground.
  • Page 29 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR M1 THREE-PHASE FAN RESISTANCE TEST (460V MACHINE) (continued) Figure F.6 – M1 fan lead location + + + NO 21 LC1D09 + + + NO 22 F-15...
  • Page 30 X-TRACTOR ® 3A NOTES F-16...

  • Page 31: F1 Thermal Circuit Breaker And Auxiliary Contacts Resistance Test

    AUXILIARY CONTACTS RESISTANCE TEST 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.
  • Page 32 BREAKER ENCLOSURE CIRCUIT BREAKER COVER SCREWS PROCEDURE 1. Remove input power to the X-Tractor 3A. 2. Perform the Case Cover Removal Procedure. 3. Locate the F1 thermal circuit breaker on the back of the machine. See Figure F.7. 4. Using a phillips screwdriver, remove the two screws securing the F1 thermal circuit breaker enclosure cover.
  • Page 33 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR F1 THERMAL CIRCUIT BREAKER AND AUXILIARY CONTACTS RESISTANCE TEST (continued) Figure F.8 – F1 thermal circuit breaker lead location LEAD #43 RED RESET BUTTON STOP START BLACK RESET GV2ME10 BUTTON LEAD #44 Table F.1 – F1 contact resistance checks TEST TEST POINT TEST POINT...
  • Page 34 X-TRACTOR ® 3A NOTES F-20...

  • Page 35: Timer T1 Test

    TIMER T1 TEST 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.
  • Page 36 10. Connect all leads previously removed. 11. Perform the Case Cover Replacement Procedure. 1. Remove input power to the X-Tractor 3A. 2. Perform the Case Cover Removal Procedure. 3. Locate the timer T1 on the DIN rail. See Figure F.9.
  • Page 37 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR TIMER T1 TEST (continued) Figure F.10 – Timer T1 lead locations A1 15 Y1 A1 15 Y1 FUNCTION TIME RANGE 16 18 A2 18 A2 Figure F.11 – Timer T1 settings FUNCTION TIME 0.1h 0.1s RANGE F-23...
  • Page 38 X-TRACTOR ® 3A NOTES F-24...

  • Page 39: Timer T2 Test

    TIMER T2 TEST 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.
  • Page 40 10. Connect all leads previously removed. 11. Perform the Case Cover Replacement Procedure. 1. Remove input power to the X-Tractor 3A. 2. Perform the Case Cover Removal Procedure. 3. Locate the timer T2 on the DIN rail. See Figure F.12.
  • Page 41 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR TIMER T2 TEST (continued) Figure F.13 – Timer T2 location A1 15 Y1 A1 15 Y1 FUNCTION TIME RANGE 16 18 A2 18 A2 Figure F.14 – Timer T2 settings FUNCTION TIME 0.1h 0.1s RANGE F-27...
  • Page 42 X-TRACTOR ® 3A NOTES F-28...

  • Page 43: K1 Contactor Tests

    K1 CONTACTOR TESTS 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.
  • Page 44 9. Check the resistance between K1 terminals 5L3 and 6T3. It should be zero ohms with the contactor activated. If not, the contacts may be faulty. See Figure F.16. See the Wiring 1. Remove input power to the X-Tractor 3A. Diagram. 2. Perform the Case Cover Removal Procedure.
  • Page 45 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR K1 CONTACTOR TESTS (continued) Figure F.16 – K1 contactor test points and lead location LEAD A1 LEADS 13 + + + NO 21 LC1D09 + + + NO 22 LEAD 14 LEADS A2 F-31...
  • Page 46 X-TRACTOR ® 3A NOTES F-32...

  • Page 47: Cleaning Solenoid Resistance Test

    CLEANING SOLENOID RESISTANCE TEST 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.
  • Page 48 TIMER CLEANING SOLENOID COIL PROCEDURE 1. Remove input power to the X-Tractor 3A. 2. Perform the Case Cover Removal Procedure. 3. Locate the cleaning solenoid. See Figure F.17. 4. Perform the Digital Solenoid Timer Removal Procedure. 5. Check the resistance of the cleaning solenoid coil. Normal coil resistance is approximately 12.5 ohms.
  • Page 49 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR CLEANING SOLENOID RESISTANCE TEST (continued) Figure F.18 – Cleaning solenoid coil terminals GROUND COIL TERMINALS F-35...
  • Page 50 X-TRACTOR ® 3A NOTES F-36...

  • Page 51: Digital Solenoid Timer Removal And Replacement Procedure

    DIGITAL SOLENOID TIMER REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 52 DIGITAL SOLENOID TIMER REMOVAL PROCEDURE 1. Remove input power to the X-Tractor 3A. 2. Perform the Case Cover Removal Procedure. 3. Locate the digital solenoid Timer. See Figure F.19. 4. Using a slotted screwdriver, loosen the screw securing the digital solenoid timer plug.
  • Page 53 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR DIGITAL SOLENOID TIMER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.20 – Digital solenoid timer plug screw location TIMER PLUG SCREW Figure F.21 – Solenoid coil location SOLENOID COIL DIGITAL SOLENOID TIMER F-39...
  • Page 54 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR DIGITAL SOLENOID TIMER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Position the new digital solenoid timer on to the solenoid coil. Note rubber washer placement. 2. Attach digital solenoid timer plug to digital solenoid timer. 3.

  • Page 55: M1 Three-Phase Fan Assembly Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 56 • Make sure to use only approved lifting gear. securing the vacuum valve t-piece to the fan assembly. See 8. Once the X-Tractor 3A is lifted and stabilized use a 17mm Figure F.23. Note washer and gasket placement for reassembly.
  • Page 57 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR M1 THREE-PHASE FAN ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.23 – Hose flange and vacuum valve t-piece location VACUUM VALVE HOSE T-PIECE FLANGE Figure F.24 – Fan leads GROUND TERMINAL + + + NO 21 LC1D09 + + +...
  • Page 58 REPLACEMENT PROCEDURE 1. Carefully position new fan assembly into the machine. 2. Using a hoist and straps, carefully lift the X-Tractor 3A so the fan assembly mounting nuts can be easily accessible. 3. Once the X-Tractor 3A is lifted and stabilized, use a 17mm deepwell nutdriver and attach the three fan assembly mounting nuts and associated washers to the bottom of the machine.

  • Page 59: Transformer Removal And Replacement Procedure

    TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 60 TRANSFORMER (LOCATED ON DIN RAIL) REMOVAL PROCEDURE 1. Remove input power to the X-Tractor 3A. 2. Perform Case Cover Removal Procedure. 3. Locate transformer on DIN rail. See Figure F.26. 4. Unscrew the vacuum relief valve to gain access to the transformer leads.
  • Page 61 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.27 – Transformer leads and removal TRANSFORMER LEADS SEC.: – MAX. LOAD 3.75A ROTATE UPWARD TO REMOVE FROM DIN RAIL. PRI.: – 460V – 480V – 500V 47-63HZ TRANSFORMER LEADS...
  • Page 62 X-TRACTOR ® 3A NOTES F-48...

  • Page 63: F1 Thermal Circuit Breaker Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 64 BREAKER ENCLOSURE CIRCUIT BREAKER COVER SCREWS REMOVAL PROCEDURE 1. Remove input power to the X-Tractor 3A. 2. Perform Case Cover Removal Procedure. 3. Locate F1 thermal circuit breaker on the back of the machine. See Figure F.28. 4. Using a phillips screwdriver, remove the two screws securing the F1 thermal circuit breaker enclosure cover to the machine.
  • Page 65 X-TRACTOR ® 3A TROUBLESHOOTING AND REPAIR F1 THERMAL CIRCUIT BREAKER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.29 – F1 thermal circuit breaker lead and mounting clip locations MOUNTING CONTACTOR F1 THERMAL CIRCUIT CLIPS LEADS BREAKER LEADS (FOUR CORNERS) GROUND LEADS F1 THERMAL CIRCUIT BREAKER ENCLOSURE CONTACTOR...
  • Page 66 X-TRACTOR ® 3A DIAGRAMS TABLE OF CONTENTS - DIAGRAMS SECTION - Diagrams ..........................Section G Diagrams ..............G-2...
  • Page 67 X-TRACTOR ® DIAGRAMS...
  • Page 68 X-TRACTOR ® DIAGRAMS...
  • Page 69 X-TRACTOR ® DIAGRAMS...
  • Page 70 X-TRACTOR ® DIAGRAMS...

This manual is also suitable for:

K3965-1K3965-2

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