Lincoln Electric X-TRACTOR 1GC Service Manual
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Lincoln Electric X-TRACTOR 1GC Service Manual

Lincoln Electric X-TRACTOR 1GC Service Manual

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X-TRACTOR ® 1GC
For use with machines having Code Numbers:
K652-1, K652-2
SERVICE MANUAL
SVM250
| Issue D ate 14-Jun
© 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 1GC

  • 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 ® 1GC For use with machines having Code Numbers: K652-1, K652-2 SERVICE MANUAL SVM250 | Issue D ate 14-Jun ©...
  • 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 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 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 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 NOTES viii...
  • Page 10 ® X-TRACTOR TABLE OF CONTENTS MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ....................................ii-viii Installation, Operation, Accessories, Maintenance ....................IM576-B Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F Electrical Diagrams ..............................Section G...
  • Page 11 ® X-TRACTOR THEORY OF OPERATION TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory Of Operation ......................Section E Input Power And Line Switch ...........E-2 High/Low Switch, PC Board, Thyristor Module &...
  • Page 12 (M2) INPUT POWER AND LINE SWITCH The X-Tractor 1GC is supplied with single phase 120 VAC or 240 VAC input power through the input line switch. 120 VAC or 240 VAC is then applied to the PC board, the high/low switch, the motor M2 and the thyristor module.
  • Page 13 ® X-TRACTOR THEORY OF OPERATION Figure E.3 - High/Low switch, PC board, thyristor module & motors M1 and M2 120/240 VAC AUTO / MANUAL SWITCH INPUT LINE 120/240 VAC POWER PC BOARD THYRISTOR SWITCH 120/240 AC CURRENT SENSOR MOTOR HIGH / LOW (M1) SWITCH MOTOR...
  • Page 14 ® X-TRACTOR THEORY OF OPERATION Figure E.4 - Auto/Manual switch & current sensor 120/240 VAC AUTO / MANUAL SWITCH INPUT LINE 120/240 VAC POWER PC BOARD THYRISTOR SWITCH 120/240 AC CURRENT SENSOR MOTOR HIGH / LOW (M1) SWITCH MOTOR 120/240 VAC (M2) AUTO/MANUAL SWITCH &...

  • Page 15: Table Of Contents

    ® X-TRACTOR TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ....................Section F How to Use Troubleshooting Guide ..........F-2 PC Board Troubleshooting Procedures .

  • 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: Pc Board Troubleshooting Procedures

    ® X-TRACTOR TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES 4. Test the machine to determine if the failure symptom has been WARNING corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

  • Page 18: Troubleshooting Guide

    5. Perform the Motor M2 (Low) Test. 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 4. Possible faulty PC board. 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 20 ® X-TRACTOR NOTES...

  • Page 21: 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 22 9. Remove the compressed air valve and leave the cleaning device in the machine. 1. Remove the input power to the X-Tractor 1GC. 10. Using a phillips screwdriver, remove the ten screws securing the 2. Disconnect the hose from the inlet on the front cover assembly, if case rear assembly to the case sides.
  • Page 23 ® X-TRACTOR TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.2– Compressed air fitting removal FRONT COVER COMPRESSED ASSEMBLY AIR VALVE LINCOLN ELECTRIC Figure F.3 – Case rear assembly mounting screws LINCOLN ELECTRIC CASE REAR ASSEMBLY MOUNTING SCREWS (TEN SCREWS TOTAL)
  • Page 24 ® X-TRACTOR TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Connect the current sensor plug to the PC board. See Wiring Diagram. 2. Carefully position the case rear assembly over the case sides. NOTE: The motors must be positioned properly to allow for the proper fit of the case rear assembly and the filter cleaning unit.

  • Page 25: Current Sensor Test

    CURRENT SENSOR 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 26 YELLOW BROWN GREY PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Check for any loose or faulty connections and/or damaged components. 4. Using a volt/ohmmeter, check voltage from Pin 3(+) to Pin 4(–) on the plug attached to the current sensor board.

  • Page 27: Thyristor Test

    THYRISTOR 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 28 (continued) Figure F.5 – Thyristor terminal and lead locations + + + PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Check for any loose or faulty connections and/or damaged components.
  • Page 29 ® X-TRACTOR TROUBLESHOOTING AND REPAIR THYRISTOR TEST (continued) Figure F.6 – Thyristor test 6 VOLT R1 = 4 OHMS/10 WATTS LANTERN R2 = 3 OHMS/10 WATTS BATTERY UNDER TEST To test SCRs construct the circuit outlined above. Resistors values are plus or minus ten percent.
  • Page 30 ® X-TRACTOR NOTES F-16...

  • Page 31: Pc Board Test

    PC BOARD 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 THYRISTOR PLUG CURRENT SENSOR PLUG PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Check for any loose or faulty connections and/or damaged components. 4. Carefully apply input power to the machine.
  • Page 33 ® X-TRACTOR TROUBLESHOOTING AND REPAIR PC BOARD TEST (continued) Table F.1 – PC board tests TEST POINT TEST POINT EXPECTED CONDITION READING (PLUG) (PLUG) AUTO/MANUAL AUTO/MANUAL 27 VDC POWER ON, MODE SWITCH IN ‘AUTO’ POSITION. PIN 5 PIN 6 CURRENT SENSOR CURRENT SENSOR 18 VDC POWER ON, MODE SWITCH IN ‘AUTO’...
  • Page 34 ® X-TRACTOR NOTES F-20...

  • Page 35: Line Switch Test

    LINE SWITCH 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 PROCEDURE 10. Connect the remaining leads to the line switch. See Wiring Diagram. 1. Remove the input power to the X-Tractor 1GC. 11. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 12. Perform the Case Cover Replacement Procedure.
  • Page 37 ® X-TRACTOR TROUBLESHOOTING AND REPAIR LINE SWITCH TEST (continued) Figure F.9 – Line switch terminal location TERMINAL 3 TERMINAL 4 TERMINAL 1 TERMINAL 2 (VIEWED FROM THE BOTTOM) F-23...
  • Page 38 ® X-TRACTOR NOTES F-24...

  • Page 39: Mode Switch Test

    MODE SWITCH 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 PC BOARD PLUG) PC BOARD PLUG) (VIEWED FROM THE BOTTOM) PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Check for any loose or faulty connections and/or damaged components. 4. Label and disconnect leads from the mode switch. See Figure F.10.

  • Page 41: Motor M2 (Low) Test

    MOTOR M2 (LOW) 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 42 12. Check resistance from either lead 2 or lead 6 to the motor case. See Figure F.11. See Wiring Diagram. Resistance should be 1. Remove the input power to the X-Tractor 1GC. a minimum of 500k Ohms. If test fails, perform the Motor 2.

  • Page 43: Motor M1 (High) Test

    MOTOR M1 (HIGH) 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 44 See Wiring Diagram. See Figure F.12. See Wiring Diagram. Resistance should read a minimum of 500k Ohms. 1. Remove the input power to the X-Tractor 1GC. If test fails, perform the Motor Removal And Replacement 2. Perform the Case Cover Removal Procedure.

  • Page 45: Current Sensor Removal And Replacement Procedure

    CURRENT SENSOR 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 46 UNDER WORK LEAD HOOK) HOOK REMOVAL PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Using a 8mm nutdriver and a 8mm open end wrench, remove the two bolts and associated washers securing the current sensor to the case rear assembly.
  • Page 47 ® X-TRACTOR TROUBLESHOOTING AND REPAIR CURRENT SENSOR REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new current sensor into the case rear assembly. 2. Using a 8mm nutdriver and a 8mm open end wrench, attach the two bolts and associated washers securing the current sensor to the case rear assembly.
  • Page 48 ® X-TRACTOR NOTES F-34...

  • Page 49: Thyristor Removal And Replacement Procedure

    THYRISTOR 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 50 THYRISTOR + + + REMOVAL PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Locate the thyristor. See Figure F.14. 4. Using a phillips screwdriver, label and disconnect leads 3, 4, 5, 6 and 8 from terminals 1, 2 and 3 of the thyristor.
  • Page 51 ® X-TRACTOR TROUBLESHOOTING AND REPAIR THYRISTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.15 – Thyristor leads, terminals and mounting nut locations MOUNTING NUTS (2) + + + REPLACEMENT PROCEDURE 1. Apply a small amount of Dow Corning 340 joint compound to the mounting surface of the new thyristor.
  • Page 52 ® X-TRACTOR NOTES F-38...

  • Page 53: Pc Board Removal And Replacement Procedure

    PC BOARD 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 54 PC BOARD + + + REMOVAL PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Locate the PC board. See Figure F.16. 4. Label and disconnect the plug connecting the line switch and the thyristor to the PC board.
  • Page 55 ® X-TRACTOR TROUBLESHOOTING AND REPAIR PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.17 – PC board plug and mounting bolt locations MOUNTING BOLTS AUTO/MANUAL SWITCH PLUG LINE SWITCH AND THYRISTOR PLUG CURRENT SENSOR PLUG MOUNTING BOLTS REPLACEMENT PROCEDURE 1. Carefully position the new PC board in the machine. 2.
  • Page 56 ® X-TRACTOR NOTES F-42...

  • Page 57: Line Switch Removal And Replacement Procedure

    LINE SWITCH 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 58 LINE SWITCH LINCOLN ELECTRIC REMOVAL PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Locate the line switch. See Figure F.18. 4. Using a slotted screwdriver, label and disconnect the black and white leads from terminals 2 and 4 of the line switch.
  • Page 59 ® X-TRACTOR TROUBLESHOOTING AND REPAIR LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.19 – Line switch lead locations 12(i) 12(k) BLACK WHITE (CONNECTED TO LEAD LEAD REAR TERMINAL) REPLACEMENT PROCEDURE 1. Carefully position the new line switch in the machine. 2.
  • Page 60 ® X-TRACTOR NOTES F-46...

  • Page 61: Mode Switch 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 62 MODE SWITCH LINCOLN ELECTRIC REMOVAL PROCEDURE 1. Remove the input power to the X-Tractor 1GC. 2. Perform the Case Cover Removal Procedure. 3. Locate the mode switch. See Figure F.20. 4. Label and disconnect the four leads from the mode switch terminals.
  • Page 63 ® X-TRACTOR TROUBLESHOOTING AND REPAIR MODE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.21 – Mode switch terminals ‘LOW MODE’ ‘HIGH MODE’ (GREY LEAD TO (BLACK LEAD TO POWER SWITCH) MOTOR M1) ‘MANUAL MODE’ ‘AUTO MODE’ (LEAD 14 TO (LEAD 13 TO PC BOARD PLUG) PC BOARD PLUG) (VIEWED FROM THE BOTTOM)
  • Page 64 ® X-TRACTOR NOTES F-50...

  • Page 65: Motor Removal And Replacement Procedure

    MOTOR 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 66 10. Using a hammer and a slotted screwdriver, remove the nut securing the input power cord to the case of the machine and 1. Remove the input power to the X-Tractor 1GC. carefully route cord and leads out of machine. See Figure F.26.
  • Page 67 ® X-TRACTOR TROUBLESHOOTING AND REPAIR MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.23 – Thyristor lead locations + + + MOTOR MOTOR M2 LEAD M1 LEAD Figure F.24 – Line switch terminal locations TERMINAL 3 TERMINAL 4 TERMINAL 1 TERMINAL 2 (VIEWED FROM THE BOTTOM) F-53...
  • Page 68 ® X-TRACTOR TROUBLESHOOTING AND REPAIR MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.25 – Mode switch terminal locations ‘LOW MODE’ ‘HIGH MODE’ (GREY LEAD TO (BLACK LEAD TO POWER SWITCH) MOTOR M1) ‘MANUAL MODE’ ‘AUTO MODE’ (LEAD 14 TO (LEAD 13 TO PC BOARD PLUG) PC BOARD PLUG) (VIEWED FROM THE BOTTOM)
  • Page 69 ® X-TRACTOR TROUBLESHOOTING AND REPAIR MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.27 – Ground lead connection GROUND LEAD REAR PANEL MOUNTING NUT WASHER Figure F.28 – Rear panel mounting locations REAR PANEL MOUNTING SCREWS F-55...
  • Page 70 ® X-TRACTOR TROUBLESHOOTING AND REPAIR MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.29 – Washer and mounting nut locations INSIDE OF REAR PANEL MOUNTING NUT WASHER REPLACEMENT PROCEDURE 11. Place the filter cleaning unit back into the machine. 12. Perform the Case Cover Replacement Procedure. 1.
  • Page 71 ® X-TRACTOR DIAGRAMS TABLE OF CONTENTS - DIAGRAMS SECTION - Diagrams ..........................Section G Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2...
  • Page 72 THYRISTOR PC BOARD (220V) SENSOR (120V) S22634 WIRING DIAGRAM FOR X-TRACTOR 1GC MANUFACTURED MAY, 1997 THRU APRIL 1999 (Machines with Low/High Switch and Circuit Breaker located under rear cover) POWER CABLE N.A. WIRE #7 CONNECTED TO AUTO PIN #1 FOR 220V MODEL HIGH N.B.
  • Page 73 ® X-TRACTOR DIAGRAMS WIRING DIAGRAM FOR X-TRACTOR 1GC MANUFACTURED AFTER APRIL 1999 (Machines with Low/High Switch and no Circuit Breaker under rear cover) N.A. WIRE #7 CONNECTED TO PIN #1 AT PC BOARD FOR 220V MODEL. POWER CABLE HIGH N.A. WIRE #7 CONNECTED TO PIN #3 AUTO AT PC BOARD FOR 120V MODEL.

This manual is also suitable for:

K652-1K652-2

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