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Lincoln Electric IM274-A User's Manual

1. P 114 H P 114 H K224 SOLID STATE REMOTE FIELD CONTROL DISCONTINUED a Zu r d rp MP i Th h i Ay ke L5297 DO Y Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 67819 Solid State Remote Field Control Includes K224 1 1 Top Door M10639 4 1 2 Terminal Strip S14530 1 1 Number Plate T10726 90 1 4 Capacitor S10593 1 5 Auto Transformer M12702 0 1 6 Box Assembly M12706 1 7 Transformer S15257 0 1 8 Capacitor T11079 1 9 Nameplate M12688 1 10 Polarity Switch S13417 0 1 11 Fuse Holder S10433 1 Fuse T10728 8 1 12 Capacitor S13490 1 1 13 Diode T12705 15 1 14 SCR and Heat Sink M13342 0 1 15 Control P C Board Code 7359 Only L5316 1 15 Control P C Board Code 7683 amp Above L5759 1 16 Caution Decal T13470 1 18 Choke S14644 1 19 Resistor Code 7742 amp Above T12731 42F 1 K224 Mounting Angles S12995 1 amp 1ea S13709 06 13 2008 0 This part is obsolete and no longer available NOTES The Lincoln Electric Company L 5249 Cleveland Ohio 44117 Dimension Print LN 8F WIRE DRIVE UNIT DIMENSIONS F 8 44 ea Front brass block Z J T for gun cable fitting 280 Dia 4 holes for mounting
2. 05 10 2005 P 107 W 1 P 107 W 1 For Assembly L4276 use the parts marked X in Column 1 For Assembly L4383 use the parts marked X in Column 2 Indicates a Change This Printing For Assembly L4383 A use the parts marked X in Column 3 ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 1 Case For Assemblies 14276 M10634 1 X 1 Case For Assemblies 14383 or L4383 A M10634 1 1 2 Capacitor T11577 37 1 3 Resistor See Below 1 X X X 4 Rectifier T13637 1 5 Cover 13153 1 6 Connector T9639 2 1 7 Transformer See Below 1 8 Fuse Nameplate 112401 0 1 X 8 Nameplate 12593 0 1 9 Circuit Breaker T12287 1 1 X 9 Fuse Holder T12386 1 X X 10 Fuse T10728 20 1 11 Fuse Holder S10433 1 X X X 12 Source Marker T10743 1 13 Number Plate T10726 30 0 1 14 Terminal Strip S8542 2 0 1 15 Equipment Marker 112256 1 16 Grommet T8965 2 17 Nameplate M10643 1 18 Copper Jumper and Heat Radiator Assembly S13472 2 2 19 Contactor S45 Order 567 300 4 1 X X L2630 S1 S45 Contactor Parts See P 28 E 19 Contactor S67 L4300 4 1 x S67
3. 5742 11 14 8606 11 86 P 110 D 1 P 110 D 1 Indicates a Change This Printing For LN 8N or NE use only the parts marked X in Column 1 For LN 8S or SE use only the parts marked X in Column 2 For LN 8F Below Code 7575 Only use only the parts marked X in Column 3 ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 1 Instrument Mounting Panel M12428 1 1 X X 1 Instrument Mounting Panel M12428 2 1 X 2 Control P C Board Insulation Above Code 7900 S15961 1 2 Control Board Insulation Below Code 7900 14819 1 3 Control Board Above Code 7900 L5767 1 1 X X 3 Control P C Board Below Code 7900 L5040 1 Plastic Expansion Nut S14020 1 3 X X X Self Tapping Screw S8025 14 3 4 Lead T13496 1 3 5 Decal Below Code 7575 and Above Code 7900 T13086 1 1 5 Decal Code 7575 thru 7900 T13086 15 1 8 Transformer amp Receptacle Assembly Above Code 7900 S14165 140 1 X IX 8 Transformer Assembly Below Code 7900 S14651 1 0 1 Transformer Insulation T14070 1 X X X 9 Relay P C Board Insulation Above Code 7900 S14820 1 1 9 Relay Board Insulation Below Code 7900 514820 0 1 11 Relay B
4. P 107 T Miscellaneous Options Mechanized Travel Power Pack 161 P 107 V a V b Power Pack Contactor Kit K124 and K130 P 107 W W 1 Contactor Kit KAO uuu uuu EEE EEEN RS aoni P 107 W 2a W 2b Parts List The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K7 1 Continued 9 67 SUA A P 28 H J b1 Mechanized Hand Travel Unit 10 P 107 X Gear Box for KIO 107 Portable Field Control K200 aaa aaaaasassassssassassassas asa P 110 Z K261 Wire Feed Speed Analog Voltmeter Above Code 7575 Only P 110 AA K262 Wire Feed Speed Electronic Voltmeter Above Code 7575 Only P 110 AA K224 Solid State Remote Field Control 114 Contactor Dropout Delay Kit nennen aa erstehen Order K202 10 to 25 Pound Spool Spindle M Order K162 Swivel Type Mounting Platon inserieren Order K178 P 103 C P 103 C K112 amp K113 Squirtguns amp Cables cz A DE Yo sr SEN we
5. L 5249 3 9 79N 90No Wiring Diagram The Lincoln Electric Company Cleveland Ohio 44117 1199 GUN CABLE CONNECTION REQUIREMENTS NOTE These are general specifications for gun cable connections with the LN 8 Contact your local Lincoln Welding distributor listed under welding in the Yellow Pages for details 747 18 9 min 62D 15 75 mm 03 x 45 07 mm x 45 06 1 5 mm 1 25 a 31 75 Dia hole 295 7 5 mm 290 7 4 min 252 Connector must be a insu anii 260 6 6 mr insulated in this area o eea 2 00 1 25 31 75 50 8 mm Gun cable connector requirements to permit proper connection to Lincoln wire feeders LN 8 amp LN 9 A Dia Hole To be Concentric to 749 747 Dia 19 18 mm Wire Size within 008 20 mm F i M 7 64 amp 120 2 8 amp 3 0 mm 152 24 drill 3 86 mm 068 thru 3 32 1 7 thru 2 4 mm 125 1 8 drill 3 18 mm 1 16 062 1 6 mm 078 5 64 drill 1 98 mm 045 amp 052 1 1 8 1 3 mm 062 1 16 drill 1 6 mm 1030 amp 035 0 8 8 0 9 mm 055 54 drill 1 4 mm LN 8 8 LN 9 Cable connector for 1 16 through 120 1 6 through 3 0 mm wire 180 4 6 mm 160 4 1 ma 03 x 45 07 mm x 45 Dia hole For all other dimensions see above 495 12 5 mm MAX Dia LN 8 amp LN 9 Cable connector for 030 through 052 0 8 through 1 3 m
6. K112 amp K113 SQUIRTGUNS amp CABLES 11 22 2005 LINCOLN 5 0 This part is obsolete and no longer available P 103 D P 103 D Gun Assembly Squirtguns K112 amp K113 WD 7 NOTE In 1977 the semiautomatic guns were redesigned to conform to NEMA standards To identify a new design gun an ampere rating is stencilled on the clamp of the Clamp amp Tube Assembly Item 2 of P 103 C For new design guns use columns 3 4 or 5 In 1979 the K112 and K113 guns were further redesigned This latest redesign may be identified by a size molded in the nozzle insulation Part of Item 2 near the handle to gun connection SQUIRTGUNS K112 8 K113 06 03 2005 LINCOLN For Squirtgun K113 use the parts marked X in Column 1 or 3 see note For Squirtgun K112 use the parts marked X in Column 2 or 4 see note For Squirtgun K112 500 Amp use the parts marked X in Column 5 see note P 103 D 1 P 103 D 1 Indicates a change this printing Use only the parts marked x in the column under the heading number called for in the model index page 0 This part is obsolete and no longer available ITEM DESCRIPTION PART NO ary 1 2 3 4 5 67 8 9 1 Cap S12955 1 114181 2 Housing amp Nozzle Asbly Includes 5 64 Stenciled M10670
7. Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 671819 Meter Kit Includes K261 1 Meter Kit Includes K262 1 1 Meter Housin L4753 g 1 2 Meter Panel M13036 1 1 3 Feed Speed Ammeter S15650 1 4 Analog Voltmeter for K261 M10486 3 1 4 Electronic Voltmeter for K262 M12995 0 1 5 Meter Guard S10509 60 1 6 Shock Mounting T13003 4 7 Polarity Switch T13381 5 1 8 Work Jack T14280 1 9 Switch Plate T13096 3 1 10 Remote Work Lead Optional for K261 S15636 1 11 Momentary Switch T10800 15 1 12 Toggle Switch 113381 1 13 Switch Plate T13096 4 1 16 Meter Shield M13044 1 17 Harness S14165 70 K262 WIRE FEED SPEED METER ELECTRONIC VOLTMETER KIT an 0 This part is obsolete and no longer available 02 20 2002
8. P 107 F 3 P 107 F 3 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 6 7 8 9 Wire Drive Motor amp Gear Box Assembly Includes LN 8N amp 8S L5743 1 1 Wire Drive Motor amp Gear Box Assembly Includes LN 8F L5743 2 1 31 Gear Box Assembly Includes M14310 1 1 1 Gear Box G1221 3 1 2 Helical Reduction Gear 13440 1 3 Pinion Gear Shaft 13441 1 4 Woodruff Key 304 1 5 Retaining Ring T8856 2 1 6 Needle Bearing S10116 4 2 7 Drive Gear S13442 1 8 Drive Shaft S13445 1 9 Woodruff Key 404 1 10 Bearing M9300 7 2 11 Snap Ring S9776 31 2 12 Beveled Snap Ring S11910 1 1 13 Plain Washer S9262 47 1 14 Lock Washer E106A 16 1 15 Hex Head Screw 3 8 16 x 625 1 16 Shaft Seal T13097 1 17 Plain Washer S9262 94 18 Shim 010 Thick S9262 50 As Req d 18 Shim 002 Thick S9262 73 As Req d 19 Spacer T11116 3 1 20 Gear Box Cover S13453 1 21 Lock Washer T9695 1 4 22 Thread Forming Screw S9225 30 4 24 Motor Insulator M13479 1 1 25 Drive Motor Assembly Includes M13327 1 1 Drive Motor Includes M13312 1 Brush amp Spring Assembly Universal Motor M12254 1F 2 Brush amp Spring Assembly Stature Motor M13312 12 2 Brush Cap Universal Motor Early Design 7 8 27 THD M9655 7A 0 2 Brush Cap Universal Motor Present Design 3 4 27 THD 9655 7 0 2 Brush Cap Stature Motor M13312 13 2 Pinion 15013 3 1 Roll Pin Pinion T9967 33 1 26 Insulation Not used on LN 8F T13911 1 27A Screw Insulator T14058 3 27B P
9. caseo Sec K6 1 5 Gun Cable Gun and Hand Travel Kit G n Cable su q u q aaa u a W aqui NR H Sec K6 2 1 Gun Disassembly Innershield Squirtguns K115 amp K126 and Submerged Arc Squirtguns K1 2 Kline aG u Sec K6 2 2 Gun Disassembly Innershield Squirtgun K116 Sec K6 2 3 Gun Nozzle s A Sec K6 2 4 Gun Disassembly Submerged Arc Squirtgun K114 tens Sec K6 2 5 Hand Travel Kit K 110 a ne u aaa qa LOOP RAN SSES as usay Sec K6 2 6 Flux Feeding Systerm eere tine e a Ee deest o Rei a s aun aaa qaa ee ee pinos Sec K6 3 1 Troublesho6ting u Sec K6 4 Electrical Sequence of Operations ooo oo Sec K6 7 Sec K7 Parts Lists u add S aS apa a Sia aan Sec K7 1 Wiring Diagrams oiean ten tenete pete re ie ee ein Filed at back of this manual November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC K2 2 MECHANICAL INSTALLATION Sec K2 2 1 Wire Feed Unit and Wire Reel 1 LN 8N wire feed unit and wire reel mount are shipped separately To connect a Remove the three 3 8 9 5 mm screws from the back of the wire drive unit b Place the wire reel mounting bra
10. 23 Button Head Socket Screw T11551 6 1 24 Collar Assembly T12341 1 26 M8776 31 1 NOTE These items are not part of assembly and must be purchased separately or in kit form 9 Idle Roll Assembly See Table 1 X X X 22 Incoming Guide Tube See Table 1 25 Drive Roll and Gear See Table 1 X X X 27 Outgoing Guide Tube See Table 1 30 Outgoing Guide Insert See Table 1 X X X WIRE CONVERSION ITEM ITEM ITEM ITEM ITEM SIZE KIT 9 22 25 27 30 030 035S KP502 0 35 S12722 035 S13492 035 S13343 035 S12548 035 S12553 035 035A KP503 035A S17731 035 S13492 035 S17729 035 S12548 035 S12553 035 045 KP502 052 S12722 052 S13492 052 S13343 052 S12548 052 S12553 052 3 64A KP503 3 64A S17731 3 64 S13492 052 NSS S12548 052 S12553 052 052 KP502 052 S12722 052 S13492 052 S13343 052 S12548 052 S12553 052 1 16S KP502 1 16 S12722 1 16 S13492 1 16 S13343 1 16 512548 1 16 S12553 1 16 1 16A KP503 1 16A S17731 1 16 S13492 1 16 17729 1160 S12548 1 16 S12553 1 16 068 KP502 3 32 S12722 3 32 S13492 3 32 T12057 3 32 12554 3 32 S12725 3 32 5 64 KP502 3 32 12722 3 32 13492 3 32 T12057 3 32 12554 3 32 S12725 3 32 3 32 KP502 3 32 12722 3 32 13492 3 32 T12057 3 32 12554 3 32 S12725 3 32 7 64 KP502 120 12722 120 13492 120 T12057 120 12554 120 12725 120 120 KP502 120 S12722 120 S13492 120 T12057 120 S12554 120 S12725 120 0 This part is obsolete and no longer available 01 01 200
11. JUGBUEJ esing 1 1 bOELd irn tono Selene coto 6t tN2Z Jogo Liens uogoe an 104 1035 LMS uno 1585 ts yequunu epoo jo sjuauoduJoo 12 eui moys siy ejajdwos e jo Al qee ueysseyum y pejuud e uo 10 ou S 4661 3 194 sjoqui s poupa UORDA0 Ay A00F vr AS IDEAS SINOS J0126 03d Buipuno s yor ueuno Bupiem pajentoe yms poc ux 1 84A NZ UHOL 10d MZ UNS NOS UZ peog ord uo10u Sins 9813 MOIS A 062 HO A 521 Vert 1023 Usi eiu mar vi 8214 vi tiia 24 Uxz vl eua OE 9219 Jawu LOS v eer pote MO Sid 002 vi RWWHLUWL Dee 6010 or ad MLUSZ DEE vi sola ZH Us 10H vol 40 07d 1218 UX 90H 9050 vi soza DSL oz sosa vi 1020 wi rosa vi 5020 MAYU Y ws vi UZ vi DuipunoJ6 aseo eu sjoeuuoo 10 28 01d pee
12. w 9B Nozzle Insert 120 T12576 3 KP2094 3 1 X X X X o 2 9B Nozzle Insert 3 32 T12576 1 KP2094 1 1 X X X X 9B Nozzle Insert 5 64 T12576 1 KP2094 1 2 e e e e je joe jo X X 9C Nozzle Insert Retainer T12977 2 1 X X X XXX XX 9D Liner Locking Screw T12932 2 1 X X X X X X X X X X 10 Trigger amp Control Cable Assembly M12462400r 15 1 X X X X X X X X X X Assembly Parts See P 103 K 11 Insulated Guide 2 3 4 Electrical Stickout S12691 1 1 XXX XXX XX 11 Insulated Guide 3 3 4 Electrical Stickout S12691 2 1 XX XX X X XX 11 Insulated Guide 1 1 4 Electrical Stickout S13358 1 X XX XX X X X 12 Contact Tip Length 1 1 8 Note 1 T14157 120 KP2103 3 X Kile X 12 Contact Tip Length 1 1 8 Note 1 T14157 7 64 KP2103 6 X s X 12 Contact Tip Length 1 1 8 Note 1 T14157 3 32 KP2103 4 X X X X 12 Contact Tip Length 1 1 8 Note 1 T14157 5 64 KP2103 5 XX 12 Contact Tip Length 1 1 8 Note 1 14157 072 KP2103 1 1 14 Switch Housing Clamp S12339 1 X XX X 14 Switch Housing Clamp S15922 1 1 XIX XIX X X 15 Shield Mounting Block Early Guns Only Not Illustrated T12385 0 1 X X X X X X X X 17 8 32 x 1 50 RHS CF000119 2 X X X X X X X X X X 17 Lock Washer T9695 3 2 X X X X X X X X X X 17
13. 94 gr se suono9uuoo Y ee Jequinu 2 19 MOPS 3 ay 12513 190 sjoqui s Je2u129 3 nde 1098301d peaj 0606 104 pue 0606 Sepoo uo pesn 101615 an A d Jeoq Onuoo Y 8 uaa pseog S31ON BUM M 8 Unys 19818W M Buipoo 10 09 pea 18jau euondo palog i Mauss E 7 Buipunos6 ese Bune due 52022571611 jueudinbe O Wee 2 seuluus JOBUUCO YNO 77929 wss 626 129 9 asry MOIS AOSZ 10 Od a hejo i 14229 ASZ due lt 26 21 z vies Work to power source 8 2 8 5 1o1581oJd pea 3 uuojsuen pieoq jo uo Suid peeg 2 Wms Popayul 5 d EI lt 6 hians 9 f xe SE9 lt y 1nchno SINOS dwe gere 9 9 lt 9 gt La m u 189 4 T lt k j E m J accu 525 Q YES Te 4 196 169 969 59 i 3 a gt 164E9 q 159 ve9 Y V V x IPS peog Pel lt 71 6
14. IX 5 Lock Washer E106A 2 3 X X IX 6 1 4 20 HN CF000017 3 X X X 7 1 4 20 x 1 50 HHCS CF000141 3 X X X 8 Insulating Washer S10773 41 12 X X IX 9 Insulating Tube T7028 90 1 X X IX 10 Reel Mounting Shaft Assembly See P 107 P 1 X X X I X 10 Reel Mounting Shaft Assembly Order K162 H 1 X 11 Cable Clamp S16819 1 XXX XX 12 Thread Cutting Screw S9225 8 2 X X 13 Insulating Tube T7028 180 2 X X X Optional Door Assembly Includes M11514 Note 1 1 X X X Door and Hinge Welded Assembly L4692 1 X X X Catch T12652 1 X X Sealing Panel S14049 1 X IX X X X Sealing Panel Mounting Plate S14067 2 X X X X X LN XNE amp LN XSE Fully Wire Reel Support Assembly Includes all Above plus L4745 0 1 X X LN 22 Fully Enclosed Wire Reel Support Assembly Includes all above plus L4745 2 1 X Hand Crank Assembly See P 107 R 1 X IX Wire Feed Unit Handle 513863 1 X X LN XNE Lightweight Wire Reel Support Assembly Includes L5369 2 0 1 eX Wire Reel L4604 1 Hand Crank Assembly See P 107 R 1 Wire Reel Support 5368 1 Wire Feed Unit Handle S13863 1 Reel Mounting Shaft Assembly For 2 1 D Spools Order K162 1 eX Reel Mounting Shaft Assembly Standard M12460 1 NOTE 1 To equip an LN 7 with a wire reel cover kit order 514543 In
15. Turn off power source before installing or servicing Do not touch electrically hot parts ELECTRIC SHOCK n Turn the input er to th can kill input power e welding power source off at the fuse box before working in the terminal strip Keep away from moving parts MOVING PARTS can injure Only qualified personnel should install use or service this equipment Sec K3 1 1 Introduction Input power 115VAC 2 5A is supplied by the Power Source Duty Cycle The amount of welding perfromed in a 10 minute period expressed nas a percentage 1 Optional Meters See descriptions in Sec K2 5 1 2 and 3 The Ammeter indicates welding current in amps The Wire Feed Speed Meter is normally used only when the LN 8 is connected to a constant voltage power source To read wire feed speed in in min rather than reading amps press the spring loaded switch next to the meter Set the range switch next to the meter to Lo when using speeds below 300 in min 7 6 m min and read the feed speed on the red 0 300 in min 0 7 6 m min scale For higher feed speeds set the range switch to Hi and read the speed on the back 0 600 in min 0 15 m min scale The Electrode Polarity Switch must be set so the analog voltmeter reads up scale or the electronic voltmeter indi cator lights operate The Analog Voltmeter indicates voltage directly on a scale To Operate the Electronic Voltmeter first
16. 11 Socket Head Cap Screw T14438 1 e XX 12 Contact Tip Length 1 1 8 Note 1 T14157 120 KP2103 3 As Regd X X 12 Contact Tip Length 1 1 8 Note 1 114157 7 64 KP2103 6 As Regd X X 12 Contact Tip Length 1 1 8 Note 1 Ti4157 3 32 KP2103 4 AsReqd X X 13 Insulated Guide 2 3 4 Electrical Stickout s12691 1 KP1965 1 1 X X X X 13 Insulated Guide 3 3 4 Electrical Stickout 12691 2 KP1965 2 1 X 13 Insulated Guide 1 1 2 Electrical Stickout 13358 KP1971 1 1 X X X Adapter Kit to Use K116 w MN 1 amp ML 3 Not Shown M10682 o 1 X X X X Adapter Kit to Use K116 with ML 2 Not Shown 512967 0 1 X X X X Specify 15 or 10 Cable as Appropriate K116 SQUIRTGUN amp CABLE 08 28 2007 LINCOLN 0 This part is obsolete and no longer available SRR RR Gk Gk P 103 H P 103 H K116 Squirtgun Handle amp Control Cable K116 SQUIRTGUN HANDLE amp CONTROL CABLE 08 26 2008 LINCOLN P P 103 H 1 Indicates a change this printing P 103 H 1 ITEM DESCRIPTION PART NO QTY 1 6 78 09 Squirtgun Handle amp Control Cable K116 Handle amp Control Cable Assembly 15 Length L5734 15 1 X Handle amp Control Cable Assembly 10 Length L5734 10 1 X Handle amp Control Cable Assembly 15 Length L4189 15 1 X Handle amp Control Cable Assembly 10 Length L4189 10
17. Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent 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 WELDING and CUTTING 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 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 Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such proce
18. Mode switches on contactor kit are not functional when used with the power source To make A feeder positive polarity and B feeder negative polari ty reverse electrode cables connected to power source output studs The Lincoln Electric Company Cleveland Ohio 44117 1199 Welding lead stud on back of contactor kit Dual process contactor GND gt wire feeder electrode positive Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts Only qualified persons should install use or service this machine or 50 HZ Operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B M14551 1 20 89B The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC K2 5 OPTIONAL FEATURES Have electrician install and service this equipment the input power off at the fuse box before working on equipment HIGH VOLTAGE Do not touch electrically hot parts can kill Sec 2 5 1 K261 and K262 Meter Kits The K261 and K262 meter kits can be installed on all mod els built to Codes above 7575 manufactured after July 1975 Installation instructions L5649 are included with the kits Both kits include a combination ammeter an
19. e Tum power off before servicing Desconectar el cable de alimentaci n de poder de ia m quina antes de iniciar cualquier servicio e D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten 0 opere com as tampas removidas e Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas gt 9 ETRAZ VFS FMT FEU 5 40 ANS ACAI EN Qi ily gS juil abii e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas Anlage nis ohne Schutzgeh use oder Innenschutzverideldung in Betrieb setzen Mantenha se afastado das partes moventes e Nio opere com os painels abertos ou Quardas removidas e 421 e MR BUT EDILES F ego Gel see X WAR 4 cuts ad a Yo ARE Linji Ad gl AVISO DE PRECAUCION French ATTENTION ATEN O Japanese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANGA DO EMPREGADOR H gt MRCBHOL A OHRBEE lt BA ETRMLTFEL TULTRHOREHELEITFE L BR EC A DO DUAE E ACRES CER t B BA CLR TREE EL SRL ITE 35 A DS ERDE AZo SSE Hyza KASAD FAL AAA erde E ce ec Saal ala jl gil al
20. K466 7 Connector Kit Hobart Series 2000 Connector Assembly Includes Set Screw O Ring 2 required Socket Key Wrench Gun Control Cable Assembly S18653 S11604 51 T13483 8 T11563 4 S18845 M18003 K466 3 Connector Kit For Miller Feeders Connector Assembly Miller Includes O Ring 2 required Connector Cap Assembly Miller Includes Set Screw Gun Control Assembly Miller Wrench Socket Key Liner Material 045 1 2 mm maximum Liner Material 1 16 1 6 mm maximum Liner Material 5 64 2 0 mm maximum S19760 T13483 8 S19761 S11604 51 M16325 S18845 11563 4 518685 12 S18685 13 S18685 14 K466 8 Connector Kit Lincoln Wire Feeders Gas Tubing Tubing Clamp 2 required Connector Assembly Includes Set Screw Insulation Tube Gun Control Cable Hose Nipple Socket Key Wrench T10642 127 T13777 4 S18645 2 S11604 51 T7028 234 M15608 T14557 7 T11563 4 S18845 K466 4 Connector Kit For Hobart Feeders Connector Hobart Connector Cap Assembly Hobart Includes Set Screw Gun Control Assembly Hobart Wrench Socket Key Liner Material 045 1 2 mm maximum Liner Material 1 16 1 6 mm maximum Liner Material 5 64 2 0 mm maximum Hose Nipple Tubing Clamps 2 required Gas Tubing S19763 S19765 S11604 51 M16328 S18845 T11563 4 S18685 15 S18685 16 S18685 17 T14557 7 T13777 4 T10642 166 K466 9 Connector Kit Lincoln SP100T SP125
21. LOADING THE MACHINE CONT D Operating Instructions The magnetic separator is used with all Lincoln mild steel flux 760 761 780 781 860 and 880 Do not use the magnetic separator with any stainless steel alloy Either turn off the incoming air line or remove the quick disconnect if one has been installed Slightly loosen the tank cap and let the air in the tank escape through the holes in the side of the cap After pressure has been released remove cap from the tank Using the funnel pro vided put 100 pounds 45 Kg of flux into the tank It is very important that only new or properly reclaimed flux be put in the tank Coarse particles and or magnetic parti cles will stop the flux feeding process New Lincoln flux is properly screened at the factory All reclaimed flux must be separately screened through a vibrated screen having 065 075 1 6 1 9 mm openings and be put through a magnetic separator The K310 vibrated screen and K58 Magnetic Separator are available for this pur pose The screen in the funnel supplied with the tank has much larger openings and its only purpose is to keep paper and slag out of the tank Screw the tank cap back on and tighten hand tight Reconnect the incoming air line to the tank There will always be a small amount of air and possibly drops of water coming out of the end of the tube coiled under the tank This is an automatic disposal system in case the plant air has water and dirt i
22. 1168 61 01 Jajdepe 0861 5 yoed 2 9 lo pu itt l 2 et lt lt jousydwe jndino 6 1 10 8 N1 9 N1 JO 1004 s nId jeu Jojo8uu07 ES Zr E The Lincoln Electric Company T12309 Cleveland Ohio 44117 1199 Wiring Diagram 10 15 821 114 GUN CABLE AND K110 DRIVE UNIT K114 Gun control cable Power Pack Start stop switch adapter receptacle 18 C 2A Ht 7 Ke xum These leads used 1211 54 only for guns equipped Y y y for travel unit 73 1 2 8 852 54 89 528 Bo 878 Travel motor Cx field Travel motor speed armature MECHANIZED TRAVEL SCHEMATIC ATMED T12834 Wiring Diagram 110AC LEN 10 15 82L 7 a Yellow 7A 43 42 11 Red Yellow Black 022 MFD 12 42 Motor field Freed back Hand travel winding unit at gun 1 8 A fuse 42 11 a 54 X Control Stabilizing winding capacitor 50 MFD m Taped red lead for 60 HZ 10W For 50 HZ operation both red amp black No 54 leads must be connected to No 54 on power pack terminal strip NOTES Do not touch electrically live parts or electrode with skin or wet clothing insulate yourself from work and ground AVISO DE PRECAUCION Sm French ATTENTION Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous tension Isolez vous du trav
23. 4 8 mm Allen wrench and pull the nozzle straight out To reinstall insert the nozzle into the gun handle Push it in as far as possible and tighten the socket head screw Remove the cable from the wire feeder To disassemble Innershield Squirtguns K115 K126 first loosen the four screws which hold the heat shield in place Remove the heat shield To disassemble the switch housing from all guns remove the four screws holding the saddle around the gun handle Then hold the housing with the cable toward the floor and look into the switch cavity The tight side of the larger roll pins is to the right Drive these pins to the left They can be easily removed when they clear the right side of the casting Do not remove the smaller roll pins unless the trigger is being replaced The height of the Z spring controls the operating point of the switch with respect to the trigger movement Set the spring so the switch operates at about the mid point of the trigger travel To remove the handle from the cable slip the spatter shield out of the front of the handle Loosen the 1 4 20 socket head screw in the side of the handle Remove the snap ring The handle and connector clamp can then be slipped off the cable November 1990 90No Sec K6 2 3 Gun Disassembly Innershield Squirtgun K116 Remove cable from the wire feeder Remove the pistol grip assembly from the gun by removing the four screws which clamp the assembly to
24. NA NOTE In 1977 the semiautomatic guns were redesigned to conform to NEMA standards To identify a new design gun an ampere rating is stencilled on the clamp of the Clamp and Tube Assembly Item 2 For new design guns use columns 3 or 4 In 1979 the K112 and K113 guns were further redesigned This lat est redesign may be identified by a size molded in the nozzle insulation Part of Item 1 near the handle to gun connection K112 8 K113 SQUIRTGUNS 8 CABLES 06 06 2005 LINCOLN 5 P 103 C 1 For Squirtgun K113 use the parts marked X in Column 1 or 3 see note P 103 C 1 For Squirtgun K112 use the parts marked X in Column 2 or 4 see note Indicates a change this printing Use only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO ary 1123456789 Gun amp Cable Assembly 5 64 Electrode No Electrode Size Stencil K113 1 Gun amp Cable Assembly 5 64 Electrode Stenciled 5 64 K113 5 64 1 X X Gun amp Cable Assembly 3 32 Electrode Stenciled 3 32 K113 3 32 1 X 1 Gun Assembly M10614 4 0 1 X X 1 Gun Assembly M10614 7 1 X 1 Gun Assembly M10614 9 1 X X 1 Gun Assembly M10614 8 1 DX Gun Parts See P 103 D 2 Clamp and Flux Tube Assembly 516165 1 X X X X 3 Handle M10102 1 XX 3 Handle M10102 1 1 I XX 4 Socket Head Cap Screw
25. Of control box same polarity Power source must be off Optional solid 1 Note Electrode polarity switches on power source and field control must be set for when changing polarity Connect the control cable ground lead to the frame ter off state control Field control minal marked 77near the power source terminal strip or 490 WARE put cable to an unpainted frame screw The power source must be ae H 4 24 1 2 31 32 75 76 77 properly grounded 11550 ERE If optional solid state motor generator field control is not 24 43 NA used tape up separately the A B 8 C leads from the 11022 11 control cable Also connect a jumper from 2 24 on the 2672 power source terminal strip 24 mE 21 N A Bolt and tape connection 1 4 lo 4 N B Welding cables must be of proper capacity for the current and lo 2 D duty cycle of immediate and future applications ol of N C Extend lead 21 using 14 larger insulated wire physically 32 tt suitable for the installation An S16586 remote voltage D sensing work lead is available for this purpose Connect it R Control directly to the work piece keeping it electrically separate from cable to the welding work lead circuit and connection For conve equip Y Connect to desired a7 automatic nience this extended 21 lead should be taped to the welding term i i hw r wal control box work lead This extended 21 lead connection replaces t
26. la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place NOTES The Lincoln Electric Company Index Cleveland Ohio 44117 1199 SEC K1 INDEX Sec K2 Sequence of Installation Mechanical Installation la Install the wire feed unit and wire reel mounting at the work station except LN 8P Sec K2 2 1 1b Install the LN 8F on the boom or fixture Sec K222 2 Install the wire feed rolls for the wire size to be used Sec K2 2 3 3 Install the gun and cable assembly l U U Sec K224 4 Connect the continuous flux feed tank submerged arc welding only Sec K22 6 5 Install the LN 8N or LN 8S input cable to the wire feed unit Sec K22 9 6
27. 0 9 1 2 mm 1 3 1 6 mm 1 6 2 0 mm 0 6 0 8 mm For cables 25 ft 7 6 m and less Trim to Fit Gas Diffuser Asbly 250A 350A Thread On 250A 350A Slip On 450A 550A Thread On 450A 550A Slip On Gas Nozzles 250A 350A Thread On 1 8 Recess KP2746 1 KP2746 2 or KP2746 1 B25 or KP2746 2 B25 KP2747 1 KP2747 2 or KP2747 1 B25 or KP2747 2 B25 CHART B Part Number Industry Ref KP2742 1 50R KP2742 1 50R B25 KP2742 1 62R KP2742 1 62R B25 English 1 0 Size Cable Liner for Aluminum For 10 ft 3 m Trim to Fit KP44 3545 25 KP44 116 25 KP44 564 25 Part Number Industry Ref KP1958 1 KP1958 5 KP1958 3 035 045 052 1 16 1 16 5 64 0 9 1 2 mm 1 3 1 6 mm 1 6 2 0 mm Metric Wire Size English Wire Size 030 035 035 3 64 1 16 0 8 0 9 mm 0 9 1 2mm 1 6 mm For 15 ft 4 5 m Trim to Fit Metric 1 D Size KP2742 1 50F KP2742 1 50F B25 KP2742 1 62F KP2742 1 62F B25 250A 350A KP1958 2 KP1958 6 KP1958 4 KP42N354515 KP1955 2 030 035 035 3 64 1 16 035 3 64 1 16 0 8 0 9 mm 0 9 1 2mm 1 6 mm 0 9 1 2mm 1 6mm CHART D KP2773 2 or KP2773 2 B25 1 8 Stickout KP2742 1 50S KP2742 1 50S B25 KP2742 1 62S KP2742 1 62S B25 450A 550A 250A 350A Slip On 1 8 Recess KP2742 2 50R KP2742 2 50R B25 KP2742 2 62R KP2742 2 62R B25 KP2742 2 50F
28. 4h WARNING Do not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts HIGH VOLTAGE can kill Turn the input power to the welding power source off at the fuse box before working in the terminal strip Keep away from moving parts lt lt MOVING PARTS can injure Only qualified personnel should install use or service this equipment Sec K3 1 8 A Wire Reel Loading 60 and 50 Pound 27 2 and 22 7 Kg Reels Loading the Reel Be sure the drive roll pressure is properly set for the wire size being used See Sec K2 2 3 a To remove the wire reel from its shaft grasp the spring loaded knob and pull it out This straightens the knob so it seats into the shaft when released b Lay the reel flat on the floor and remove the cover plate c Place a coil of wire on the reel so it unwinds as the reel rotates clockwise A Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires B When loading 035 045 and 052 0 9 1 1 and 1 3 mm L 50 wire be certain the coil is placed on the reel so the spring loaded arms are at the center of 90No the slots in the cardboard coil liner This provides the positive compression of the coil needed for trou ble free wire feeding C Put the cover plate on the reel so the four arms of the cover straddle
29. 8 32 HN CF000042 2 X X X X X X X X X X 18 CCC Decal Not Shown T13086 192 1 X X X X X X X X X X Adapter Kit to use K115 Squirtgun with MN 1 amp ML 3 Not Shown 10682 0 1 X X X X X X X X X X Adapter Kit to use K115 Squirtgun with ML 2 Not Shown 512967 0 1 X X X X X X X X X X SQUIRTGUN amp CABLE 08 28 2007 P 103 G P 103 G K116 Squirtgun amp Cable NOTE 1 For old contact tips length 7 8 used only with nozzles made before Fall 1968 order T12236 120 T12236 7 64 T12236 3 32 fo lt 0 22 RZ A SO AB O 2 Note In 1977 the semiautomatic guns were redesigned to conform to NEMA standards To identify a new design gun an ampere rating is stencilled in the handle of Assembly Item 7 For new design guns use columns 3 or 4 K116 SQUIRTGUN amp CABLE 06 06 2005 LINCOLN For 120 amp 7 64 Electrode Gun use the parts marked X in Column 1 or 3 See Note P 103 G 1 Indicates a change this printing For 3 32 Electrode Gun use the parts marked X in Column 2 or 4 See Note P 103 G 1 Use only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO aTY 1 2 34 5 6 7809 Gun amp Cable Assembly 120 amp 7 64 Electrode K116 120 1 Xie X Gun amp Cable
30. Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER o TRANSFORMATEUR ETA a Utiliser un bon masque avec un verre filtrant approprie REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de et des projections quand on soude ou quand on regarde 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 8 Relier
31. Axle Housing S13953 1 x 7 Wire Reel Cover Back M11574 2 2 X 8 Self Tapping Screw 8025 22 4 X 9 Spring T11862 8 1 X 10 Plainwasher S9262 45 1 X 11 Insulating Washer S10773 49 1 x 12 Hex Head Screw 5116 18 x 75 1 X Lockwasher E106A 3 1 X Plainwasher S9262 61 1 X 13 Wire Reel Cover Front M11574 2 1 X 14 Axle Nut S13956 1 X 20 Housing Cover M11578 1 x Decal 118932 1 x 21 Cover Retaining Strap Assembly S15891 1 X 22 Cable Clamp S16819 1 X Thread Cutting Screw S9225 8 2 x 23 Coil Support Disc S17060 1 x 24 Thread Cutting Screw S9225 30 2 x 05 09 2002 0 This part is obsolete and no longer available P 107 P P 107 P WIRE REEL SHAFT 5 7 8 1 2 0 4 12460 For All LN 6 LN 7 LN 8S 8 8SE LN 9S 9 9SE 9NE 9NH and LN 22 use Column 1 For LN 8F LN 9F and LN 9FH use Column 2 Indicates a Change This Printing For SP 200 use Column 3 ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 Reel Mounting Shaft Assembly Includes M12460 1 X Reel Mounting Shaft Assembly Includes M12908 1 Reel Mounting Shaft Assembly Includes M12460 1 1 e X 1 Hex Head Bolt 1 2 13 x 1 00 1 X X X 2 Lock Washer E106A 15 1 4 Brake Assembly Includes S14882 1 X 4 Brake Assembly Includes S14882 1 1 XIX Brake T13519 1 Cotter Pin S10750 19 1 X
32. KP2742 2 50F B25 KP2742 2 62F KP2742 2 62F B25 KP2773 1 or KP2773 1 B25 CHART E KP2925 60 300 Amp 1 8 Stickout KP2742 2 50S KP2742 2 50S B25 2742 2 625 2742 2 625 25 450A 550A Thread On 1 8 Recess KP2743 1 62R KP2743 1 62R B25 KP2743 1 75R KP2743 1 75R B25 KP2743 1 62F KP2743 1 62F B25 KP2743 1 75F KP2743 1 75F B25 1 8 Stickout 2743 1 625 2743 1 625 25 2743 1 755 2743 1 755 25 450 550 1 8 Recess KP2743 2 62R KP2743 2 62R B25 KP2743 2 75R KP2743 2 75R B25 KP2743 2 62F KP2743 2 62F B25 KP2743 2 75F KP2743 2 75F B25 1 8 Stickout 2743 2 625 2743 2 625 25 2743 2 755 2743 2 755 25 MAGNUM 300 8 400 GMAW GUN LINCOLN 5 KP2926 60 400 Amp 05 03 2010 NOTES MAGNUM 300 4 400 GMAW GUN LINCOLN 5 P 110 C P 110 C LN 8 WIRE FEED UNIT Except LN 8F SIDE VIEW BACK VIEW L5741 B 11 14 86F 11 86 P 110 C 1 P 110 C 1 Indicates a Change This Printing ITEM D
33. Sec K3 1 4 Linc Fill Long Stickout Welding The built in controlled acceleration of the LN 8 wire feed motor gives good starting with normal stickout and Linc Fill long electrical stickout procedures No rewiring is needed Simply install the proper stickout extension on the gun set the procedures and weld The electrode should be lightly touching the work when the trigger is pressed When submerged arc welding using 3 1 4 80 mm stick out and a constant current power source at currents over 500 amps there may be a tendency for the electrode to blast off in the extension guide at the start This problem can be corrected by reducing the current to 500 amps for the start When the arc starts quickly increase the control setting as desired for welding Do not change any other control Installation of the K200 or K224 field control is required when using motor generator power sources to have output control at the wire feeder If the electrode continues to blast off a slower accelera tion can be obtained by modifying the LN 8 Codes 7926 and up as follows 1 Turn off the control power to the LN 8 at the power source 2 Remove five screws holding the control section cover in place and swing upward 3 Move the jumper plug on the control P C board from pin F to S 4 Reassemble November 1990 NOTES The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions LOADING THE MACHINE
34. all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information E SAFETY PRECAUTIONS DE S RETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits a l lectrode et la piece sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine a souder en bon et s r amp tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les pa
35. and case of operation Even if the horizontal surface is not available using the roller guide without the rear wheel still aids in making fillet welds If the nozzle extension used with long stickout proce dures is installed replace item 15 with the long guide roll arm item16 This is shipped loose with the fillet guide kit See following drawing M9715A B 90No Operating Instructions 2 Operation After the Fillet Guide is installed with the rear wheel placed as required for the application see Installation proceed as follows a Position the travel unit so the nozzle flux cone is at the right height to deposit enough flux to cover the arc b Inch the electrode out so the point will just miss touching the plate when the gun is held in the proper position for welding The electrode end should slight ly favor the horizontal plate The nozzle flux cone should miss the vertical plate by about 1 32 0 8 mm The gun handle must be 90 to the vertical plate when looking down from above Be certain the elec trode has not been bent when making these adjust ments c Hold the gun in proper position for welding Lower the rear wheel until it touches the horizontal plate Lock it into position The adjustment range of the rear wheel can be increased by moving the wheel from position A to B If using the nozzle extensions for long stickout procedures replace item 15 with the long guide roll arm item 16 d
36. extension use 23 1 2 7 2 m order 5906 106 45 13 7 m extension use 46 14 m order M5906 104 To mount the wire drive unit handle provided with the extension unit remove the two self tapping screws that hold the hinge pin in the top of the wire feed unit Push the hinge pin out leaving the covers intact Place the handles into the slots provided push the hinge pin back into the assembly making sure the pin goes through the holes in the handle Put the two self tapping screws back into the respective positions If the extension is being used with a K306 Wire Reel Flux Tank assembly the hose attached to the bottom of the flux tank may have to be shortened This hose is 64 feet 19 5 m long and is the correct length for use with the 45 foot 13 7 m extension If a 22 1 2 foot 6 9 m extension is to be used cut off 22 1 2 feet 6 9 m of the flux hose to give the correct length of 41 1 2 feet 12 6 m The conductor cable of the extension assembly is 22 1 2 feet 6 9 m long tip to tip and can be used to measure the length cut off If the flux hose is taped to the exten sion cables or the gun cable it should be done in such a manner as not to deform or collapse the flux hose November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC K2 3 ELECTRICAL INSTALLATION WARNING Turn the power source of
37. zg5rc GE Variable Voltage P C Board d optional gt 2 o 2 a 4 20220 a Thermal breaker 5 o m m mi se had 7 sh ER a 528 x 5 1 o J 9554135 627 626 zx 5 55 z s Z gt 5 Wiro feed motor 025 7 2 541 x S gt 568 567 GND Ea v Meter kit receptacle 5 8 ot 63 4 1 8 7 5 9 2 9 2 Work 22 27 E a 9 5 115 V A C 31 and 32 gers 285 To power source work terminal 5 ga 5 96465 Jumper connector is removed and connector is plugged into 2 69 optional burnback p c board m Actuated by motor temperature A N E l Electrical Symbols per E 1537 5 29 81F 85Ap equinu apoo eu 10 81 01 9114 51 ay sjaued a nsopus y jo euo uo ay episui pejsed si po5 Je noyuede 10 2 ay SIUJ Aq 10 jou 1 1 UO 4 104 SI LUBJBEIP 5141 3 LON Wvuovia NER MD PLUS e 3S8 S8 3N8 NE N1 89 NOS OJ Y jo epis jueuoduioo J0j2euuoo epnjoui jou pue SI 18409 SIEJSOGUU eouenbes ueg AA AO palesu 5
38. 16 2007 LINCOLN For 120 amp 7 64 Electrode Gun use the parts marked X in Column 1 3 5 or 7 a LINCOLN This nart is nhsnlate and no available P 103 F 1 For 3 32 Electrode Gun use the parts marked X in Column 2 4 6 or 8 P 103 F 1 For 5 64 Electrode Gun use the parts marked X in Column 9 or 10 Indicates a change this printing ITEM DESCRIPTION PART NO ary 12345678910 Gun amp Cable Asbly 82 Nozzle 120 amp 7 64 K115 120 1 X X Gun amp Cable Asbly 82 Nozzle 3 32 Wire K115 3 32 1 X e Xie Gun amp Cable Asbly 82 Nozzle 5 64 Wire K115 5 64 1 je X Gun amp Cable Asbly 45 Nozzle 120 amp 7 64 Wire K115 45 120 1 X X Gun amp Cable Asbly 45 Nozzle 3 32 Wire K115 45 3 32 1 s fe s Gun 4 Cable Asbly 45 Nozzle 5 64 Wire K115 45 5 64 1 X 1 Conductor Cable Includes L4230 5 or 10 1 X XXX 1 Conductor Cable Includes L5728 5 or 10 1 XX X X 1 Conductor Cable Includes L5728 7 or 14 1 e X X Handle Wire Feeder End M14048 1 X X X XXX X X X X Connector Wire Feeder End S12801 6 1 Connec
39. 2 inch 25 mm in diameter by 3 inches 75 mm long Replace the output shaft assembly With a wire or screw driver work the grease around the input worm gear to apply a thin coat of grease to this gear Replace the motor assembly Check the travel motor brushes every three months November 1990 The Lincoln Electric Company Maintenance Cleveland Ohio 44117 1199 SEC K6 4 TROUBLESHOOTING WARNING ELECTRIC SHOCK can kill Do not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts Turn the input power to the welding power source off at the fuse box before working in the terminal strip Keep away from moving parts lt MOVING PARTS can injure Only qualified personnel should install use or service this equipment Sec K6 4 1 LN 8 Troubleshooting Guide TROUBLE cause WHAT TO DO 1 Drive rolls turn but wire will not feed or Gun cable kinked and or twisted a Keep as straight as possible Inspect cable and wire feeding is rough or uneven replace if necessary b Remove wire from gun and cable feed in new wire Note any obstruction Replace gun and cable if necessary c Be sure the wire diameter being used is stamped on drive rolls and guide tubes Replace if neces Wire jammed in gun and cable c Incorrect drive rolls and guide tubes sary
40. 25 2006 TRIGGER amp CONTROL CABLE ASSEMBLY LINCOLN P 103 K 1 P 103 K 1 Use the parts marked X in column 1 for K112 K113 K115 K126 Indicates a change this printing K183 K289 amp K206 guns Use the parts marked X in column 2 for K264 K345 K355 amp K361 guns ITEM DESCRIPTION PART NO 1 23456789 Trigger amp Control Cable Assembly Includes M12462 15 1 X Trigger amp Control Cable Assembly Includes M12462 10 1 Trigger amp Control Cable Assembly Includes M12462 8 1 eX 1 Micro Switch T12485 1 X X 2 Housing L10706 1 X X 3 Trigger Assembly S23982 1 X X 4 Cord Clamp T11669 2 1 X X 5 Spring T12025 1 6 Roll Pin T9967 52 1 T 3 48 x 75 RHS CF000312 2 XX 8 Switch Insulation S14878 1 X X 9 Set Screw S11604 22 1 X X 12 Polarized Plug Wire Feeder End Not Shown Old Style S12020 6 1 12 Polarized Plug Wire Feeder End S12020 16 1 eX 12A Clamp at Polarized Plug Old Style Not Shown S12024 1 1 12A Clamp at Polarized Plug 12024 4 1 eX Molded Plug Kit Includes 519757 1 X X 13A Connector Body NSS 1 X X 13B Connector Cover NSS 1 13C Connector Pin NSS 2 XX 13D Insulating Washer NSS 1 X X 13E Strain Relief Not Shown NSS 1 X X For earlier design straight pull non pivoting trigger contact Service Department for replacement parts TRI
41. 3 1 x Connector Assembly 400A 15 Cable L7773 4 1 X Connector Assembly 300A 12 Cable L7773 5 1 x Connector Assembly 400A 12 Cable L7773 6 1 X Connector Assembly 400A 20 Cable L7773 7 1 X Connector Assembly 400A 25 Cable L7773 8 1 X Includes 1 Incoming Connector Assembly S18789 1 X 2 Connector Nut 300 Amp S18749 1 2 X 2 Connector Nut 400 Amp S18749 2 2 X 3 Cable Handle L7725 1 X 4 Cable Assembly Includes 4A 300 Amp 10 Ft Cable L7761 3 1 X 300 Amp 12 Ft Cable L7761 17 1 X 300 Amp 15 Ft Cable L7761 4 1 X 400 Amp 10 Ft Cable L7761 5 1 X 400 Amp 12 Ft Cable L7761 18 1 X 400 Amp 15 Ft Cable L7761 6 1 X 400 Amp 20 Ft Cable L7761 19 1 X 400 Amp 25 Ft Cable L7761 20 1 X 4A Terminal For Mating Gun Connector End S19492 1 2 X 5 Spring Boot S24676 2 X 6 Strain Relief Housing S18786 1 X 7 Strain Relief S18787 2 X 8 Gun Tube Connector Assembly Includes S18655 1 X Gun Tube Connector M15635 1 X Tube 518847 1 X O Ring T13483 8 1 X Nozzle Clamp S15921 2 1 X Clamping Screw T14438 1 X Retaining Ring S9776 7 1 X 9 Spring Boot Retainer S24678 1 X 10 Incoming End Nut 300 Amp S23822 300 1 X 10 Incoming End Nut 400 Amp S23822 400 1 x 11 Strain Relief Housing S24677 1 X MAGNUM 300 8 400 GMAW GUN 05 03 2010 LINCOLN 8 P 202 C 4 P A RTS P 202 C 4 CHARTA CHART C Cable Liner Part Number English Metric For Steel Industry Ref Wire Size Wire Size Contact Tips Part Number E
42. 7 1 X X 2 Housing amp Nozzle Asbly Includes 3 32 Stenciled M10670 6 1 e X e 2 Housing amp Nozzle Asbly Includes M10670 4 0 1 2 Housing amp Nozzle Asbly Includes M10670 5 1 E X 2A Nozzle S13813 1 1 X X X 2A Nozzle 3 32 S13813 3 1 Xi 2A Nozzle 5 64 S13813 4 1 X 2A1 Nozzle Liner Tight Wound Steel Spring For 5 64 No Stencil KP2095 1 1 X X 2A1 Nozzle Liner Tight Wound Steel Spring For 5 64 Stenciled KP2095 12 1 X 2A1 Nozzle Liner Tight Wound Steel Spring For 3 32 Stenciled KP2095 11 1 e X 2A1 Nozzle Liner Tight Wound Steel Spring T12931 3 1 X X X 2A2 Ceramic Insert KP2094 2 1 e X 2A3 Insert Retainer T12977 1 1 2 4 Hollow Lock Set Screw T12932 1 1 X X X X X 2B Housing S13486 1 0 1 X X 2B Housing S13486 2 1 X X X 3 Collar S12964 1 1 X X X X X 4 Nozzle Flux Cone S12957 1 2 KP1968 1 1 XXX XX 4 Nozzle Flux Cone S12957 5 8 KP1968 5 1 X XX XX 4 Nozzle Flux Cone S12957 3 4 KP1968 4 1 X XXX X 4 Nozzle Flux Cone S12957 13 16 KP1968 2 1 XXX XX 4 Nozzle Flux Cone S12957 15 16 KP1968 3 1 X XXX X 4 Chamfered 3 4 Nozzle Flux Cone T14278 1 X X X X X 5 Contact Tip 1 16 Electrode T12011 1 16 KP2086 2 X X 5 Contact Tip 5 64 Electrode T12011 5 64 KP2086 4 5 Contact Tip 3 32 Electrode T14050 3 32 Note 1 T14050 3 32 lies X 5 Contact Tip 3 32 Electrode T12011 3 32 1 KP2086 3 1 X 5 Contact 1 16 Electrode T14050 1 16
43. All Submerged Arc Machines T10642 82 0 1 Flux Hose 45 Ft Req d For All Submerged Arc Machines T10642 83 1 Electrode Cable 22 1 2 Ft Req d On All Machines Above 450 Amps M5906 106 1 Electrode Cable 45 Ft Req d On All Machines Above 450 Amps M5906 104 1 Specify Cable Length and Maximum Current Draw Thru Cable Specify 22 1 2 Ft or 45 Ft as appropriate Q This part is obsolete and no longer available 07 26 2005 P 107 O P 107 O 50 AND 60 WIRE REEL SUPPORT L4699 07 26 2005 107 0 1 Indicates a Change This Printing 107 0 1 For LN 6N 65 7 8 85 9HN and 95 K303 Wire Reel Open Shroud use Column 1 For Enclosed LN 6NE 8NE 9NE and 9SE use Column 2 For LN 7 K376 Wire Reel No Shroud use Column 3 For lightweight LN 6NE 6SE 8NE 9NE and 9SE use Column 4 For LN 22 use Column 5 For K445 use Column 6 ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 LN 6 LN 7 LN 8 amp LN 9 Wire Reel Support Assembly Includes 14699 2 1 XIX X LN 7 Wire Reel Support Assembly Includes L4959 2 1 LN 7 Wire Reel Support Assembly Includes 14959 3 1 41 111 X 1 Wire Reel 14604 1 X X X XIX 1 Wire Reel S18179 1 X 2 Wire Reel Housing For LN 7 K376 Reel See Note 1 S13858 1 X IX 3 Reel Support L4680 1 XXX XX 4 Plain Washer S9262 23 6 X X
44. Code 7575 Only L5126 1 Instrument Panel Assembly Below Code 7575 Only See P 110 D 1 Instrument Panel Assembly Above Code 7575 See P 110 G 1 Terminal Strip Assembly With Leads S14896 1 1 Number Plate T10726 83 1 5 Resistor S10404 75 1 Insulating Washer T4479 A 2 Round Head Screw Resistor Mounting 10 24 x 5 1 3 Decal T13086 3 1 5 Box Cover 14771 1 6 Dial Plate M12229 1 7 Volts Potentiometer T10812 40 1 8 Amps Potentiometer T10812 71 1 8 Potentiometer Knob T10491 2 Insulation T12792 1 2 LN 8 Nameplate S14629 1 Control Box to Wire Feed Unit Cable Assembly Not Illustrated Includes Below Code 7900 L5156 15 1 Control Box to Wire Feed Unit Cable Assembly Not Illustrated Includes Above Code 7900 5814 15 1 Control Cable Includes Below Code 7900 L5156 B 15 1 Control Cable Includes Above Code 7900 L5814 B 15 1 Female Polarized Plug 90 12022 8 1 Electrode Cable Below Code 7900 L5156 C 15 1 Electrode Cable Above Code 7900 L5814 C 15 1 Wire Feed Unit Assembly Includes Below Code 7900 M11813 1 Wire Feed Unit Assembly Includes Code 7900 to 8825 M14508 1 Wire Feed Unit Assembly Includes Above Code 8825 M11813 1 1 Wire Drive Assembly Includes Below Code 7900 L4477 3 1 Wire Drive Assembly Includes Code 7900 to 8825 L5744 2 1 Wire Drive Assembly Includes Above Code 8825 L6823 2 1 Wire Drive Assembly Parts See Model Index 1 Connection Box Assembly Includes Below Code 7900 M118
45. IN3ISNVHL LOLdL 1029 90 5 420982 LOLNO 5059 18545 E00 vor OWN 900 020 EZLUNZ 200 5050 G3WOS 029 SZLvNZ LOLO 25 344500 9020 03420 2029 logo 03005 5020 QJdWos 1029 HIN9 S 1011 peog eiqeueA z peog 11241 896 peiedunf sI g oi 3utod un u p jl e1su JOU Si SIU 8 N1 erejedo o SILT JO 1yBu o ejqeueA DIPEWSYSS uqe1 do 0 ZLGLS 995 O d jeuondo 8 10 29UU09 pue si odunr YN SOJON 12 199 OND Jayeaug J0128jo1d QNO ELLH 60LH 6010 801H ot 1010 9014 9010 Solu sold pola EOLH cold zola cold 101 qa soo 6015 JN 0 8010 010 ELLO ZLLO 111090110 9010 SOLO JN v POLO 0LF 012 2019 an 1010 preog J6ye8Jq dure 10708301 AND JOJDEJU0O ayesado 21 05 Jamod S 5 15803 The Lincoln Electric Company Cleveland Ohio 44117 Wiring Diagram 10 15 82L K 161 POWER PACK WIRING DIAG
46. Note 1 T14050 1 16 X Nozzle Extension K113 5 64 1 3 4 Stickout S13027 4 1 X X Nozzle Extension K113 3 32 1 3 4 Stickout S13027 5 1 X X Nozzle Extension K113 3 32 2 1 8 Stickout S13027 3 1 X X Guide Tips for Long Stickout Extensions K113 5 64 KP2104 2 1 X X Guide Tips for Long Stickout Extensions K113 3 32 KP2091 1 1 X X Guide Tips for Long Stickout Extensions K113 3 32 T14435 3 32 1 X X As Required 1 To be used only when using S13027 5 extension NOTE 1 When tip life is limited by tip being fused over the use of T14726 tips may result in a lower overall cost SQUIRTGUNS K112 8 K113 08 28 2007 LINCOLN P 103 E P 103 E K114 Squirtgun amp Cable K114 SQUIRTGUN amp CABLE 07 18 2005 LINCOLN P 103 E 1 Indicates a change this printing P 103 E 1 Use only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO aTY 1 2 34 5 6 7 8 9 Squirtgun amp Cable K114 1 Nozzle Flux Cone 13 16 Opening Opt S12957 13 16 KP1968 2 1 X 1 Nozzle Flux Cone 5 8 Opening Std 812957 5 8 KP1968 5 1 X 1 Nozzle Flux Cone 3 4 Opening Opt 812957 3 4 KP1968 4 1 X 1 Nozzle Flux Cone 15 16 Opening Opt S12957 15 16 KP1968 3 1 X 2 Contact T12236 3 32 KP2088 2 X 2 Contact T
47. RHS CF000135 2 X K114 SQUIRTGUN amp CABLE 08 28 2007 LINCOLN P 103 E 2 Indicates a change this printing P 103 E 2 Use only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO 1 234567819 41 Lock Washer T9695 10 2 X 42 2 56 HN CF000136 2 X Nozzle Extension 2 1 4 Stickout Not Shown S12891 1 1 X Housing S13028 1 1 X Insert T12329 1 1 X Tip T12328 3 32 1 x Nozzle Extension 3 1 4 Stickout Not Shown S12891 2 0 1 X Housing S13028 2 1 X Insert T12329 2 0 1 X Tip T12328 3 32 1 X Adapter Kit to use Squirtgun K114 w MN 1 amp ML 3 Not Shown KP24A 62 1 X Adapter Kit to use Squirtgun K114 w ML 2 Not Shown 512967 0 1 X 0 This part is obsolete and no longer available K114 SQUIRTGUN amp CABLE LINCOLN 09 25 2008 NOTES K114 SQUIRTGUN amp CABLE LINCOLN 103 K115 Squirtgun amp Cable NOTE 1 For old contact tips length 7 8 used only with nozzles made before Fall 1968 order T12236 120 T12236 7 64 T12236 3 32 NOTE In 1977 the semiautomatic guns were redesigned to conform to NEMA standards To identify a new design gun an ampere rating is stencilled on the Switch Housing Clamp Item 14 For new design guns use columns 5 6 7 8 9 or 10 SQUIRTGUN amp CABLE 07
48. Table A 1 X X X X X X X XIX X X X X X Moving Contact Assembly Includes See Table A 1 J X XIXIX X X X X X X X X X X X 12 Moving Contactor Block 3 pole M6892 D 1 X X X X X XI X X 12 Moving Contactor Block 2 pole M6892 E X X XI 13A Moving Interlock Contact Assembly See Table A 1 X X X IX X X X X X 13B Moving Interlock Contact Assembly See Table A 1 X XIXIX X X X XIX X X X X X X 14 Round Head Screw 6 32 50 X X X X X X IX X X I X 15 Spring Main Contact T9029 As Reqd X X XIXI X X X X X X X X X X 16 Moving Contact T9865 4 AsReqd X X X X X XIX X X X X X X X 16 Moving Contact T9865 2R AsReqd jt X X 17 Lockwasher 106 13 AsReqd X X X X XIX X X X X X Main Contact Block Assembly Includes See Table A 1 J X XIXIX X X X X X X X X X X X 18 Main Contact Block L4305 1 X X X XXX X X 18 Main Contact Block M10681 1 X X 19 Main Stationary Contact 58029 18 AsRed X X X X X XX X X X X X X 19 Main Stationary Contact S8029 3 AsReqd X 20A Hex Jam Nut Brass T10940 3 Read X X X X X X IX IX IX X IX IX X X X 20B Hex Jam Nut Steel T10940 4 X X X XIX X X X X X X X 22 Spacer Washer T12595 AsReqd X X X X XIX X X X X X X X X X Contact
49. To operate contactor a om Be AA 32a 531 2 502 4 5041 lt DS af 21 75 76 77 2 GND 32 ret tts c a 9 O 9 Q Q o Jumper connector a gt 32 31 5 AMP 32A 531 2 502 4 504 g Power source 32a Circuit Connector output control breaker Lo m KMB io z Interlock Ground lead 7e switch Gun trigger switch gd protector m gt 524 528 4CR 2CR Reed switch 2 s 5 of Low voltage Trigger transformer 5 5 2 58 Bolted EL connection e 8 524A0536 525 529 526 531A 32A 522 7 502 5 2 531A OCR 504 ES 7 LL Quick connect terminals on board for s e gp m 1 Relay P C Board connection of auxiliary equipment o 5 5 115 V A C 0 25 amp rating So 2 627 32A 626 5 5 683 627 682 _ 2 7 8 55 5 Direction wry REV lt Meter of wire 7 c shunt feed switch 7 Wire feed Qv speed pay control o x 7631 632 634 7 7 32 s g Control P C Board 541 ih E 635 636 697 stt 59 sang NSA Connector A Jumper connector is removed and 2 oy connector A plugged into 9506 DE vec 5 AC optional variable voltage power S 6 Ey Qo 21 635 636 637 source board 3520 S 5 gt 4 9 Jumper connector 5055 RE ER waj zi 8 25958 57 go it ttt 2 22595 52 p 567 635 636 637
50. W 2 a CONTACTOR KIT K240 5360 6 20 865 6 20 86 P 107 W 2 b P 107 W 2 b Indicates a Change This Printing 0 This part is obsolete and no longer available ITEM DESCRIPTION PART NO 67819 1 Case 12799 1 2 Power Source Lead 15017 12 1 3 Contactor Jumper S13472 3 2 4 Equipment Lead S15017 11 1 5 Warning Decal T13470 1 6 Wraparound L4397 1 0 1 7 Nameplate M12802 1 10 Power Source Marker T10743 1 10 Rivet T8973 2 11 Auto Equipment Marker T12256 1 11 T8973 2 12 S67 Contactor Early Machines 14300 35 1 14300 35 Contactor Parts See 28 12 S78 L6200 4 1 L6200 4 Contactor Parts See P 28 J 13 Relay S10834 1 1 13 Rubber Chassis Mount T10325 1 4 14 Printed Wiring Diagram 15371 1 16 Stud T6931 11 2 17 Hex Jam Nut 1 2 13 4 18 Lock Washer E106A 5 2 19 Flat Washer S9262 1 4 20 Insulating Washer S10773 9 2 21 Insulating Panel T14373 2 22 Insulating Tube T14374 2 23 Connecting Strap T8141 2 24 Flange Nut T3960 2 25 Self Tapping Screw S8025 65 2 06 12 2001 P 28 H P 28 H S67 STARTER 10 26 2004 P 28 H 1b P 28 H 1b Use only the parts
51. a ireen tetaan iaai Sec K2 5 6 K202 Contactor Dropout Delay Kit For Squirtmobile and or Electrode Overrun Sec 2 5 7 K178 Mounting Platform LN 8 on Idealarc 38 Sec K2 5 8 10 and 25 Ib 4 5 and 11 Kg Spool Spindle w sssssssssssssssscsssssessssssssescsssssccccssssecccsssvscesssnsescsssnscecsensseesees Sec K2 5 9 Wire Reel Enclosure Door sscscsscssscssssssesesescssecsnsssscosensensnssvenssscnseesonensosonsaansssnenssessoussneneesceeeeeaeeees Sec K2 5 10 Undercarriage LN 8N or LN 8NB nenne neenon Sec K2 5 12 K200 Portable Field Control With SAF 600 SA 800 or SAN Only Sec K2 5 13 Variable Voltage Conversion Parts eee eee eee esses teens Sec K2 5 14 K224 Solid State Field Control With SAF 600 SA 800 or SAN Only Sec K2 5 15 K317 Dual Process Kit no polarity change Sec K2 5 16 K318 Dual Process Contactor Kit with polarity change Sec K2 5 17 Sec K3 Operating Instructions Control Adjustments and Loading the Machine iR S
52. a new handle design The new handle is ergonomically styled combining form and func tion The guns cables and connectors provide excellent performance and serviceability Magnum guns are capa ble of welding with either solid or flux cored wire elec trode using the GMAW Gas Metal Arc Welding or FCAW GS Gas Shielded Flux Cored Arc Welding pro cesses For wire sizes 035 through 5 64 0 9 through 2 0 mm see bulletin E893 for more details The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC K2 2 MECHANICAL INSTALLATION CONTINUED Sec K2 2 4 Continued November 1990 Sec K2 2 6 LN 8S and LN 8SE Continuous Flux Feed Submerged Arc 1 Flux Hose Connect the loose end of the hose to the tube at the back end of the welding gun Tighten the hose clamp If the hose is taped to the gun cable be sure it is not collapsed or deformed because this could cause flux feeding prob lems 2 Input Air Connection See S14121 for installation of K320 Flux Tank to wire feeder with K163 undercarriage The air for the automatic flux feeding system is obtained from the regular plant compressed air system providing the plant system pressure is between 60 and 120 psi 414 and 827 kPa The tank is equipped with a pressure regu lator to reduce the input pressure to the 30 psi 207 kPa required for the flux feeding system This pressure is set at the factory before the machine is shippe
53. copper bleeder may be clogged Be certain that a slight amount of air is escaping from the crimped end of the copper tube below the flux tank November 1990 The Lincoln Electric Company Maintenance Cleveland Ohio 44117 1199 SEC K6 7 LN 8 ELECTRICAL SEQUENCE OF OPERATION LN 8 SEQUENCE OF OPERATION Tum on power source Press Gun Trigger Closes 524 528 Energizes 1 CR Closes 2 4 Circuit Opens 682 683 a Closes 683 324 Circuit Energizes power source pilot relay 263 Reverses wire Energizes control circuit ibed molor power source and aux equipment if field contactor connected to 7 32A Electrode now hot to ground Wire feeds down Arc starts Energizes 2 CR Reed Switch Motor accelerates Interlocks 1 CR if to welding speed interlock switch is closed Welding Continued on next page 90No Maintenance The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K6 7 Continued Welding Release Break Gun Trigger Welding Arc De energizes Opens 2 8 Note 1 2CR Reed ce Opens Interlock on 1 CR Note 2 De energizes 1 CR Opens 2 4 Circuit Opens 531 7 Opens 683 32A Circuit Closes 682 683 Disconnects motor armature and control circuit from De energizes input AC line de energizes power source aux equipment if connected pilot relay Reverses Note 3 De energizes Motor Field Reed Switch power source momentarily contactor closes Dynamic brake
54. either a constant voltage or constant current power source Be sure both the power source and the wire feeder are properly set for the required procedure See Sec K2 3 2 November 1990 Sec K2 3 2 Connection of Input Cable to Power Source LN 8N LN 8NE and LN 8F Use a constant voltage type power source If the LN 8 has been converted to weld with a constant current power source use the instructions for the LN 8S below 1 If using a multipurpose power source DC 600 SAM SA 800 SAF 600 be sure it is properly set for con stant voltage welding per instructions in the power source operating manual 2a Connect the LN 8 input cable to the power source exactly as specified on the appropriate connection diagram in Sec K2 3 3 Include all jumpers on the terminal strips as shown on the diagrams 2b To connect to Lincoln power sources not equipped with an output contactor order a K240 Contactor Kit and see 515416 connection diagram in Sec K2 3 4 A 2c To connect to power sources equipped with a contac tor but not included in Sec K2 3 3 see K2 3 4 B for connection instructions 3 Connect a work lead of sufficient size and length per the table on the next page between the To Work stud on the power source and the work Be sure the connection to the work makes tight metal to metal contact LN 8S and LN 8SE Or converted LN 8N LN 8NE or LN 8F 1 Use either a constant voltage or constant current type power sou
55. hand and the cable handle item 28 in the other Pull the two units apart using a slight back and forth motion To disassemble the gun proceed as follows 1 Using a pair of needle nose pliers lift the end of the spring item 9 out of the hole in the trigger bar item 10 2 Loosen the gun tube clamping screw item 3 and remove the gun tube A slight back and forth twisting action will help Maintenance Sec K6 2 4 Continued 3 Remove both the screws item 21 which hold the two plastic halves together After these screws have been removed the left and right gun mounts items 6 and 11 can be separated and the remaining parts the noz zle item 4 gun hanger item 18 and the flux tube assembly item 7 can be removed To disassemble the gun handle from the cable proceed as follows 1 Remove the flux hose from the gun 2 To remove the flux tube item 29 take out the two flat head screws item 32 The flux tube can then be removed by pulling it straight back Be careful not to damage the ends of the tube 3 To remove the cable item 31 from the handle take the snap ring item 34 off the end of the brass con nector With the clamping screw item 33 loose the cable item 31 can then be pulled back out of the handle 4 Remove the switch remove the three round head screws item 37 This will allow the switch mounting plate item 36 to be removed from the fiber handle Remove the two small screws item 40
56. installed use the field control rheostat mounted to the side of the LN 8 2 1f the K224 Solid State Field Control see Sec K2 5 15 is installed use the LN 8 Amps control 3 If neither field control is installed use the Voltage control on the power source 2 Making Test Welds 5 64 2 0 mm electrode with 3 4 19 mm stickout 90 a Be sure the power source and wire feeder properly set for constant current welding see Sec K2 3 2 b Set the polarity switch on the power source for positive polarity c Set the Voltmeter Polarity switch so the voltmeter reads up scale d Set the Direction of Wire Feed switch so the wire feeds out of the gun e Set the power source for about 500 amps If using a SAM power source set the LN 8 Amps control to 5 f Set the LN 8 Volts control to 5 g Set up and ground a piece of at least 1 2 13 mm steel scrap Cut the wire at the gun to a sharp point using a pair of side cutters or diagonal cutters Improperly clipped electrode may produce poor starts and arcing of the contact tip Do not let the clipped end of the wire fall back into the gun h Hold the gun over the work allow a mound of flux to form press the trigger and start the arc by scratching through the flux See How To Make Submerged Arc Welds for additional submerged arc techniques i Adjust welding current and voltage when welding as needed November 1990
57. marked X in the column under the TABLE heading number called for in the model index page ITEM DESCRIPTION PART QTY A DIEJFI IGH J K L IMIN P Q S67 Starter Assembly Includes Less NVR TableA 1 X X X X X X X X X X X X X X X 1 Moving Lamination Assembly S12851 1 XX XX XIX X X XX X X X X X 2 Screw Lamination Mounting T9031 1 XX X X X X XX XXL KX 3 Lockwasher T9695 1 1 XX XX XIX X X XX X X X X X 3A 10 Lockwasher E106A 1 1 X X X X X X X X X X X X X X 3B 10 Hex Nut CF000011 1 X X X X X X X XXX X X X X X 4 NVR Coil Not Included L4300 Assembly See Winding Specs 1 X1X X X X X X X X X IX IX X X X 5 Lamination amp Panel Assembly 40 Hertz amp Over 6888 9 1 X X X X X X XIX X X 5 Lamination 4 Panel Assembly Under 40 Hertz M6888 100 1 X X X X X XIX X XI X 5 Lamination amp Panel Assembly M6888 120 1 X X Plastic Insert S10425 1 X X X X X XXX X 6 Contact Block Cover M10667 1 XX X X X X X X X X X X 7 Plain Washer S9262 121 2 X X X X X X XiX X IX X X X X 8 Hug Nut T9187 2 X X X X X X XiX X X X X X X X 9 Stationary Interlock Contact Assembly See Table A 1 X XIXIX X X X XIX X X X X X X 10 Stationary Interlock Contact Assembly See
58. modes Innershield or Submerged Arc The kit can also be connected to operate with the same polarity on each wire feeder The kit is rated 600 amperes at 100 duty cycle Maximum versatility is obtained when the kit is used with a DC 600 power source The following chart shows the advantage that a DC 600 has over other welders Voltage Range Mode Change 06 400 06 600 SAF 600 or SA 800 with K224 Full Solid State Remote Control Power Source The output range is limited by the voltage change obtainable by the remote control The voltage range between the two proce dures required may be outside the range covered by the remote control and it would be impossible to set the procedure without adjustment at the power source Although designed primarily for use with the LN 8 or LN 9 wire feeders the kit will also work with two LN 7 s when they are used with two remote control units Installation If it is desired to mount the K318 on top of a DC 600 an 516552 mounting bracket is available Refer to the following connection diagrams to connect the dual process contactor kit to the power source and LN 8 or LN 9 wire feeders To connect the two wire feeder control cables remove the cover from the contactor kit for access to the terminal strips Run the cables through the two box connectors then under the L shaped brackets mounted on the bottom to keep the cables away from the contactors Connect the
59. need to employ the remote work lead accessory on LN 8 meter kits which have a direct work lead jack Connect to desired electrode terminal AAWARNING Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts ELECTRIC SHOCK Only qualified persons should can kill install use or service this machine If a variable voltage board is present in the NA 3 automatic con trols the jumper lead on the V V Board must be connected to pin LH If using an older control cable Connect lead 75 to 75 on Term strip Connect lead 76 to 76 on Term strip Connect lead 77 to 77 on Term strip Connect the control cable ground lead to the frame terminal marked 777 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N B Extend lead 21 using 14 or larger insulated wire physically suitable for the installation An 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically sep arate from the welding work lead circuit and connection For convenience this extended 2 extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 8 met
60. on the brake assembly is required If the brake shoe wears through to metal replace the brake assembly November 1990 Sec K6 1 4 Control Box Every six months open and inspect the control section The accumulated dirt should be gently blown off all of the elec trical components Be sure the air that is being used is dry Check relay contacts August 1973 Sec K6 1 5 Circuit Protection Field Circuit Fuse The fuse inside the control box protects the field circuit This fuse blows if the field shorts or if one of the field cir cuit components on the relay P C board fails Motor Thermal Protection The temperature sensing thermal protector mounted in the motor opens the relay circuit when the motor overheats because of excessive loading or frequent triggering This protects the motor without nuisance tripping The thermal protector automatically resets itself after the motor cools sufficiently may take 10 15 minutes Reset time can be shortened by cooling the motor with an air hose or fan Circuit Breaker The 5 amp circuit breaker located above the drive rolls nor mally trips only when an overload occurs because of exces sive loading in the wire feed cable or a defective motor or control component After allowing a minute for cooling push the reset button and weld If it trips again be sure the wire feed cable is clean and the proper size for the wire diameter being fed If it still trips look for a defective elec
61. or the control P C board is replaced November 1990 Sec K2 5 2 K165 Ammeter Voltmeter Kit Obsolete For all models except LN 8F built to codes under 7575 manufactured before August 1975 The kit included a voltmeter ammeter voltmeter polarity switch and mounting parts Installation instructions were included with the kit June 1975 Sec K2 5 3 Obsolete K207 Wire Feed Speed Meter Voltmeter Kit For LN 8N and LN 8NE models built to codes under 7575 manufactured before August 1975 The kit included a wire feed speed meter and range switch a voltmeter and polarity switch mounting parts and a cali bration tool Installation and calibration instructions M12657 were included with the kit Because of the variations in wire feed motors calibrate the wire feed speed meter when the kit is installed The meter should need recalibration on y with major changes in feed speeds addition or removal of 22 1 2 or 45 6 9 or 13 7 m extension cables NE or SE or replacement of the feed motor November 1990 Assembly and Installation Sec K2 5 4 Equipment Contacts The power for 115 volt AC auxiliary equipment can be obtained from the terminals inside the control box The contacts are hot only when the welding circuit is on Rectangular Hole under Auxiltary Equipment Contacts 7 m The current draw of this circuit must not exceed 1 4 ampere CAUTION Do not connect
62. since there is no vertical plate to lightly hold the cone against keeping the proper electrode angle must be done by eye The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K3 2 3 Continued Figure 7 Positioned Fillet Weld Attach the positioned fillet adapter Rotate the travel unit and adapter so the drive wheel rides in the seam ahead of the weld Position the gun with the gun nozzle perpendicu lar to the seam Guide the gun with two hands Tilt it slight ly forward in the direction of travel when making the weld November 1990 Sec K3 2 4 Fillet Guide Optional K70 The Fillet Guide is designed to help guide Squirtgun K114 so the operator can make more uniform horizontal fillet welds with less effort It consists of a vertical plate roller guide and a rear wheel assembly Once the roller guide and rear wheel are adjusted the weld is easily made by gently pushing the gun into the fillet The operator does not have to constantly control the drag of the flux cone against the vertical plate nor carefully watch the angle of the gun 1 Installation Squirtgun K114 Fit the vertical plate roller guide directly on the gun noz zle Clamp the rear wheel to the gun as shown in the sketch es Use of the rear wheel requires a riding surface under the handle 7 to 11 inches 180 to 280 mm from the verti cal plate Exact location of the rear wheel is not critical However the greater distance provides better stability
63. the travel and start the arc Guide the gun with two hands Place one hand on the gun to steady it Place the other hand on the cables just back of the gun handle When making the weld lean the gun slightly forward into the direction of travel Let the weight rest on the drive roll Let the travel unit do the work Figure 4 and Figure 5 Horizontal Fillet Weld Arrow shows direction of travel Position the gun so the electrode feeds directly into the cor ner of the seam Do this with the electrode sticking out and the flux valve closed This position is usually obtained when the gun handle is approximately perpendicular to the vertical plate Once the correct angle is established guiding is accomplished by keeping the flux cone lightly in contact with the vertical plate Be sure the travel guide wheel is par allel to the seam Operate the gun trigger to open the flux valve start the travel and start the arc Guide the gun with two hands Place one hand on the gun to Steady it Press down lightly with this hand to increase the weight on the drive roll Place the other hand on the cables just back of the gun handle When making the weld lean the gun slightly forward into the direction of travel Let the weight rest on the drive roll Let the travel unit do the work Figure 6 Horizontal Lap Weld Arrow shows direction of travel The above horizontal fillet weld instructions also apply in making horizontal lap welds However
64. the handle To disassemble the switch remove the one screw which holds the housing in the pistol grip handle Slip the alu minum housing out of the handle Hold the housing with the leads toward the floor and look into the switch cavity The tight side of the larger roll pins is to the right Drive these pins to the left They can be easily removed when they clear the right side of the casting Do not remove the smaller roll pins unless the trigger is being replaced The height of the Z spring controls the operating point of the switch with respect to the trigger movement Set the spring so the switch operates at about the midpoint of the trigger travel To remove the handle from the cable follow the instructions in the last paragraph of Sec K6 2 2 August 1973 Sec K6 2 4 Gun Disassembly Submerged Arc Squirtguns Remove the cable from the wire feeder To disassemble the gun from the conductor cable proceed as follows refer to Sec K7 2 page E 1 Be sure the air is off and the pressure is released from the tank 2 If the gun still has filler wire in it clip the end of wire and back the wire out of the gun 3 Loosen the screw holding the travel receptacle clamp item 8 Do not remove the nut from the screw This will allow the clamp and the travel plug to swing free 4 Loosen the electrical connection clamping screw item 33 5 With the trigger bar item 10 in the off position grasp the gun tube item 5 in one
65. the power source contactor to these terminals see Sec K2 3 4 B Turn the power source off Install 1 4 6 0 mm quick connect terminals to the leads from the auxiliary equipment Route the leads through the rectangular hole in the back of the control panel and con nect to terminals 432A and 7 on the bottom PC board November 1990 Squirtmobile Sec K2 5 5 Squirtmobile The Squirtmobile is a self propelled trackless carriage that carries the K114 submerged arc gun on long welds for automatic welder economy without high fixture costs The Lincoln Electric Company Cleveland Ohio 44117 1199 To use the LN 8S or LN 8SE with the Squirtmobile install a K161 Power Pack Kit per Sec K2 5 6 August 1974 Sec K2 5 6 K161 Mechanized Travel Power Pack The K161 power pack supplies the power needed by the K110 mechanized hand travel unit or Squirtmobile when used with the K114 submerged arc welding gun With the power source off connect the leads of the power kit box the one with the handle to the power source Extend the control cable to the wire feed unit Mount the small box at the end of the cable to the front of the LN 8 wire feed unit the K161 is not designed for use with an LN 8F Connect the K114 gun control cable to the polar ized plug built into this small box Complete installation instructions are shipped with the kit December 1981 Se
66. the two proce dures required may be outside the range covered by the remote control and it would be impossible to set the procedure without adjustment at the power source Although designed primarily for use with the LN 8 or LN 9 wire feeders the kit will also work with two LN 7 s when they are used with two remote control units or with two NA 3 s NA 4 s or 5 90No MODE SWITCHES O SUBMERGED ARC A CV INNERSHIELD POWER SOURCE MODE SWITCH MUST BE IN CY INNERSHIELD POSITION LINCOLN DUAL PROCESS KIT THE LINCOLN ELECTRIC CLEVELAND OHIO U S A sem Closeup of controls for the K317 dual process kit Note when used with a DC 600 each mode switch should be set in the proper position for the process being used K317 mode switch es have no function with any other power source INSTALLATION Refer to the following connection diagrams to connect the Dual Process Kit to the power source and LN 8 or LN 9 wire feeders DC 400 M14549 DC 600 M13751 R3S and SAM M13702 SAF 600 or SA 800 with Solid State M13701 Remote Field Control Front of DC 600 Turn the power source off On the DC 600 fasten the adapter plate of the Dual Process Kit to the control terminal strip side of the power source using two roof screws and one front panel screw On all other power sources remove the adapter plate from the Kit and fasten Kit to the side of the power source or some convenien
67. to electrical ground per the power source operating manual N E If using an older LN 8 control cable Connect lead 75 to 75 on terminal strip con nect lead 76 to 76 on terminal strip connect lead 77 to 77 on the terminal Strip N F The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual White jumper on voltage board to pin S Blue jumper on voltage board later units only or on start board earlier units to pin B N G If lead 21 is to be connected to the terminal strip connect to the 21 terminal Does not apply to DC 400 that matches work polarity This connection must be changed whenever the elec below code 9200 with polari trode poiarity is changed 17373 ty switch 8 26 88A The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K2 3 3 L K318 Dual Process Contactor Kit Assembly and Installation DC 400 CV 400 and 500 Connection to LN 8 or LN 9 for the same Polarity Operation Welder control cable 21A 218 AUF To negative output To positive output stud on power stud on power source source Ace T work N A A Connect the control cable ground lead to the frame terminal marked near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Extend lead 21A amp 21B using 14 or larger insulated wire phys ically suitable for the installation An 516586 remote voltage sensing work l
68. welding see Sec K2 3 2 b Set the polarity switch on the power source for positive polarity With an Idealarc R3S connect the electrode cable to the Positive stud c Set the Electrode Polarity switch on the optional meter kit so the voltmeter reads upscale d Set the Direction of Wire Feed switch so the wire feeds out of the gun e Set the power source for about 30 31 volts Set the LN 8 Volts control to 6 f Set the LN 8 Amps control to 4 g Set up and ground a piece of 3 8 1 2 9 5 13 mm scrap steel Inch the electrode so it extends about 1 2 3 4 13 19 mm beyond the end of the gun for starting Hold the gun with the electrode just off or lightly touching the work Do not push the wire into the work Press the gun trigger to start to weld See the Innershield Welding Guide for detailed Innershield welding techniques i Adjust the electrical stickout and the actual welding current and voltage as needed November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions SEC K3 OPERATING INSTRUCTIONS CONT D Sec K3 1 3 Welding With Constant Current Power Sources 1 Adjusting Current and Voltage Volts Control All Power Sources Set the welding voltage with the LN 8 Volts control Amps Control DC 600 Power Source Place mode switch in the CC submerged arc position Place machine output contr
69. y ol gl gi canal aiy LINCOLN amp World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
70. 062 1 6 mm cored wire use the 1 16 drive roll The idle roll pressure should be set with wire in the system For 1 16 1 6 mm solid wire the indicator should be lined up with the solid 1 16 mark For 062 1 6 mm cored wire adjust the idle roll pressure so that the indica tor is lined up with the cored 3 32 2 4 mm mark These indicator settings are accurate enough so that there is no need to readjust unless the elec trode 1s unusually soft For wire sizes from 068 through 120 1 7 thru 3 0 mm idle roll pressure should be set with wire in the system For solid wire the indicator should be lined up with the solid wire settings For cored wire the indicator should be lined up with the cored wire settings When using 7 64 2 8 mm diameter Innershield wire adjust the idle roll pressure so that the indicator 1s between the 120 and 3 32 3 0 and 2 4 mm setting Assembly and Installation Sec K2 2 3 Continued The indicator settings for these larger wire sizes are accurate enough so that there is no need to readjust unless the electrode is unusually soft The drive rolls are stamped with the wire size for which they are designed If a wire size is used that is not stamped on the drive roll the drive rolls and guide tubes will have to be changed August 1996 Sec K2 2 4 Gun and Gun Cable 1 Gun Handling Procedures to Avoid Wire Feeding Problems a Do not kink or pull cable aroun
71. 1 X 1 Handle Mounting Bracket 512905 1 X 3 Socket Head Cap Screw T9447 36 2 X 4 Socket Head Cap Screw T9447 22 2 X 5 8 32 x 5 RHS CF000033 12 X 6 Handle Pivot Block S12690 2 X 7 8 32 x 625 FHS CF000147 2 X 8 Lock Washer T10441 1 2 X 9 Insulating Pad T12241 1 X 10 8 32 x 5 FHS CF000146 3 X 11 Lock Washer T4291 A 2 X 12 8 32 HN CF000042 2 X 13 Control Cable Includes 15 Length M10427 15 1 X 13 Control Cable Includes 10 Length M10427 10 1 X 13A Micro Switch T12485 1 X 13B Polarized Plug Wire Feeder End S12020 6 1 X 13C Clamp at Plug S12024 1 1 X 14 Friction Bushing T12233 2 X 15 Handle Pivot Shaft T12239 1 X 16 Snap Ring S9776 25 2 X 17 Trigger Assembly S23982 1 X 19 Spring T12025 1 X 20 Trigger Mounting Block Straight Pull Trigger S12688 1 X 20 Trigger Mounting Block Pivoting Trigger M18910 1 X 21 Gun Shield L4188 1 X 22 3 48 x 75 RHS CF000312 2 X 24 Handle S12687 1 1 x 25 Switch Insulation S14878 1 X 26 Roll Pin T9967 52 1 x For earlier design straight pull non pivoting trigger contact Customer Service for replacement parts 08 26 2008 116 SQUIRTGUN HANDLE amp CONTROL CABLE LINCOLN amp P 103 J P 103 J K126 Squirtgun amp Cable Note 1 For old contact tips length 7 8 used only with nozzles made before Fall 1968 order T12011 5 64 T12011 3 32 T12011 068 Note 2 When tip life is limited by tip being fused over the use of T14726 0 tips may result in a lower overal
72. 1 using 14 or larger insulated wire physically suit able for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience this extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 8 meter kits which have a direct work lead jack N B Tape up bolted connection 514609 4 20 79 Sec K2 3 3 D ELECTRIC SHOCK can kill WARNING Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts Only qualified persons should install use or service this machine Connection of LN 8 to SAF 600 O or OF SA 800 O or OF or SAF 600 B OA Welder e Older LN 8 control cables are tagged 75 Power Source 76 and 77 instead of A B and Control cable 2 To LN 8 input cable plug Electrode cable to wire feed unit Connect the LN 8 control cable ground lead to the frame terminal marked 7 near the power source terminal strip or to an unpainted frame screw The power source of course must be properly grounded When using optional K200 Portable Field Control Remove jumper 2 24 Use this lead to jumper 22 3
73. 12 1 Connection Box Assembly Includes Above Code 7900 M11812 1 1 Connection Box 14825 1 Terminal Strip S14872 1 1 Number Plate Below Code 7900 T10726 82 0 Number Plate Above Code 7900 T10726 120 0 1 Box Cover 113193 Male Polarized Plug Input S12021 1 1 Female Polarized Plug Gun Control Cable S12021 3 1 Collar Assembly Drive Roll Mounting 112341 1 Button Head Socket Screw Drive Roll Mounting T11551 6 1 Key Drive Roll Mounting M8776 31 1 0 This is obsolete and no longer available 08 09 2001 P 110 F 5815 3 31 83 LN 8F CONTROL BOX Above Code 7575 pl P 110 F 3 83 P 110 F 1 P 110 F 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 67819 1 Control amp Shunt Assembly Includes 5564 0 1 Control Box 5563 1 Meter Shunt S15716 1 Insulation Sheet Under Shunt M13106 1 Insulating Tube Shunt Mounting T7305 22 2 Insulating Washer Shunt Mounting S10773 14 4 2 Box Cover Below Code 9900 M13107 0 1 2 Box Cover Above Code 9900 13107 1 0 1 3 Door Cover Pan
74. 14 is designed for use only with the continuous flux feed sys tem If the flux tank is not used with the K112 and K113 guns attach the optional gravity feed flux cone 119 to the gun with the screws provided The cone also includes a new clamp to be used to hold the trigger pod to the gun Use it in place of the clamp shipped with the gun Innershield Guns Squirtgun K126 is recommended for most welding with 062 through 3 32 1 6 through 2 4 mm wire Install insulated nozzle extension or thread protector and the nozzle contact tip for the stickout and wire size being used For heavy duty welding with 3 32 2 4 mm wire use either Squirtgun K115 3 32 K115 45 3 32 or K116 3 32 16 has an adjustable handle and is used for higher welding currents 115 is lighter Install 3 32 2 4mm contact tip and the insulated nozzle extension for the stickout being used For welding with 7 64 and 120 2 8 and 3 0 mm wire use K115 120 K115 45 120 or K116 120 Install the insulated nozzle extension and the contact tip for the stickout and wire size being used Linconditioner Guns For locations where smoke accumulation is a problem and conventional exhaust systems are ineffective the available smoke removal type Innershield guns and vacu um units can be used Instructions are shipped with the equipment Magnum Guns Magnum 300 and 400 represent a line of gas shielded welding guns utilizing
75. 14T 116 B100 1 16 For 15 ft 4 5 m KP1958 2 030 035 0 8 0 9 mm Trim to Fit KP1958 6 035 3 64 0 9 1 2mm KP1958 4 1 16 1 6 mm KP42N354515 035 3 64 0 9 1 2mm KP1955 2 1 16 1 6mm Notched KP2010 4B1 035 Aluminum 5B1 3 64 CHARTD Gun Tube Part Number Gas Diffuser Asbly KP54A or KP54A B25 025 5 64 Gas Diffuser Asbly KP2024 2 or 2B1 025 035 0 KP1928 1 400 amp 2 300 amp CHART B 45 KP1929 1 400 amp 2 Gas Nozzles Part Number English Metric SPAM Insulator Industry Ref 1 0 Size 1 D Size 82 1941 1 300 400 Adjustable Slip On KP24A 62 Requires Nozzle KP24A 50 Insulator Assembly CHART E Connector Kits Trigger Gas Tube Product Feeder Power Lead and Connector Number Type Connector Connector Fitting Tools Recessed Slip On KP24A 62 SS Requires Nozzle KP24A 50 SS Insulator Assembly KP24A 37 SS Nozzle Insulator KP34A or KP34A B25 Assembly K466 1 Lincoln Fixed Nozzle KP23 37 Tip Recessed 12 in KP23 50 3 mm for KP23 62 Spray Transfer KP23 75 KP23T 37 K466 2 Tweco Adapted Lincoln 10 Series K466 3 Miller K466 4 Hobart 27 Fixed Nozzle Heavy Duty KP23H 62 Recessed 12 in 3mm 1954 2 Spray Transfer K466 5 L Tec Adapted Fixed Nozzle KP23 37F Tip Flush for KP23 50F Short Circuiting KP23 62F Transfer KP23 75F K466 6 Wiremat
76. 181 1Ea JO 4 pa quJesse eiqe 1 84A 3402 SEM jenuew siy au ay 1e ul Jo weu eip 5141 vota zoea 6059 5 9s voto s m NOILOJLOHd IN3ISNVHL HJWHOJSNYVHL 357 LEL Im LOEND 5219842 EGEENZ ESI 3 Jed SIOQUI S e9u199 3 MS YOL9313S 5 u3MOd 706 AOL HOLIMS NOILO3HIQ 1046 AZO HOJIMS HOOTHSINI 1446 25 089 HOLIMS NOD 1595 15 OLEY V USL 6054 vi 301931044 GVITONIGNNOYD HOP UHIWWNIHLUNS 8064 vi IN3HHNO A8 G3LVNLOV HOLMS U00L 2063 vi MZUA Y 9064 OJO HJWHOJSNVHL APZ OLL IL UXEE SCEH YZJUNS E troed OJNLEVO MZ UNO 028 2 UNI GjJNWLO MZ UNS 64 92 0495 2068 CGAWOL MOSUC UNS 9 2 UNS9 NOLLO31OHd INSISNVEL 10241 pes En hee 102826 H A VOS ZlH UNLZ 3Sn4 MOTS a i ee 082 HO ASZL 1024 HJWWIHLUAL MUSZ 5219 UNCE LOEdL sre UNOL USI LOELd UNSL 1219 UNL 2020 Uc roy UNSL 021 020 UXZ ad UNO nn UNZZ zuy wy 65 UNED M gozq H3AHOJSNvHL 3STnd ELEL LOLId 20106 2020 vi toza Vcl LOLHOS loca NOLLO31OHd
77. 2 Connect leads 2 and 24 from the portable field control to 2 and 24 on the power source termi nal strip If the portable field contro will not be mounted on the LN 8 wire feeder connect the green lead from the portable field control to the frame of the power source by means of the frame stud near the terminal strip or other secure connec tion to the power source frame If the portable field control is mounted on an LN 8 tape up the green lead from the portable field control N A Extend lead 21 using 14 or larger insulated wire physically suitable for the installation 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically sepa Auto Connect to rate from the welding work lead circuit and connection For convenience this equip Y desired electrode extended 21 lead should be taped to the welding work lead This extended term L terminal 21 lead connection replaces the need to employ the remote work lead accessory on LN 8 meter kits which have a direct work lead jack S14614 N B Tape up bolted connection 4 20 79 Work terminal To work The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K2 3 3 E Assembly and Installation Connection of LN 8 to a SAF 600 O or OF or SA 800 O or OF Using a K224 Solid State Field Control SAF 600 or X SA 800 O or
78. 294 MAKING SUBMERGED ARC WELDS Gun Operating Positions K114 Squirtgun The K114 Squirtgun is used either with or without the mechanized hand travel unit K110 With the LN 6 LN 8 and LN 9 a K161 Mechanized Travel Power Pack must be installed when using the K110 Since the travel unit assures uniform travel at the maximum usable speed and reduces the tendency to waver off the seam it is recom mended for most applications The following photographs show suggested gun positions to produce the best welds in the least time For proper flux feeding these same positions should be maintained when the gun is hand held and the mechanized travel is not used Figure 1 and Figure 2 Travel Unit Adjusting Loosen the motor mounting wing nut to adjust the travel unit Figure 1 Move the travel unit up and down or around the gun nozzle to suit different welding applications Figure 2 Pull the motor controlled plug out to remove the travel unit from the gun 90No Operating Instructions Flux Depth The depth of the flux pile is controlled by the gun height Gun height is measured from the lower tip of the nozzle flux cone to the plate Proper gun height is the height at which a minimum of flux is used without excessive arcing As a general rule the required gun height increases as the travel speed decreases and the voltage and current increase On some fillet welds a drag technique without the travel unit is used In this instance
79. 37 Connector Cavity Number Connection as viewed from back of rheostat E 683 7 682 i 32A 531 504 4 602 2 Connector PY ARTS Bumback amp variable 543261 EVAAA A 531 504 604502 2 NG Jumper connector is removed amp connector B plugged into optional bumback P C board m back P C board optional Relay amp control board 14 14710 25 25811 36 3 6 912 Pin side of connector Cavity numbering sequence component side of board Lead Color Coding B Black G Green R Red W White U Blue Y Yellow 12 5 85J M 13170 Diagram The Lincoln Electric Company Cleveland Ohio 44117 LN 8F CONTROL BOX DIMENSIONS SZ b t pue SOYIU u SUOISUJUIP v oe AW s see Se L Lepe S L Byw 10 s lou ww 7 Mee O IEL W BuimEJQ ww Lp 192 e goi 40 1018 po 8 99 wr PE Se i B 1 B 8 222 7 01 9 pG Sz Lami y eel y 09 525 pS2 _ w sez 0001 M 14676 Wiring Diagram LN 8F OPERATING SCHEMATIC The Lincoln Electric Company Cleveland Ohio 44117
80. 604 28 X 7 Reed Switch Energizer Assembly Includes S13920 7 Reed Switch Energizer Assembly Includes Below Code 7900 S14623 X 7 Reed Switch Energizer Assembly Includes Above Code 7900 S14623 1 X Reed Switch 513913 Reed Switch Below Code 7900 S14622 X Reed Switch Above Code 7900 S14622 1 X X X eX eX eX 8 Shunt Assembly Not Illustrated M11502 X X 10 Button Head Socket Screw T11551 5 11 Pivot Pin Below Code 8715 T12206 3 X X X 11 Pivot Pin Above Code 8715 T12206 2 12 Yoke Assembly 513454 13 Hollow Set Screw Below Code 8715 S11604 8 X X X 13 Hollow Set Screw Above Code 8715 S11604 35 0 14 Head Cap Screw 1 4 20 x 2 00 15 Lock Washer E106A 2 X X X 16 Plain Washer S9262 23 X X X 19 Incoming Conductor Block L6872 1 X X X 21 Locator Bushing T12189 28 Incoming Wire Guide T12272 29 Outgoing Conductor Block L6872 2 38 Gear Box Mounting Plate M11460 39 Gear Box Insulation M12137 41 Feed Unit Mounting Bracket LN 8F Only M12616 tX Thermostat LN 8 Only Below Code 7900 Not Illustrated 13359 1 R A BL lo lo lo NOTE These items are no longer part of assembly but they are included with parts orders of entire assembly
81. 7 NSS Not sold separately NOTES P 107 J AMMETER VOLTMETER KIT 1 i AMPS AN gt gt P 107 J Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 6 7 8 9 Meter Kit Includes Order K197 1 1 Meter Housing L4753 1 2 Meter Panel M11487 1 3 Ammeter M10485 4 1 4 Voltmeter M10486 3 1 5 Polarity Switch Plate T13096 1 6 Polarity Switch T13111 1 9 Shock Mounting T13003 4 11 Cable M11521 1 12 Lead Clip T12563 4 2 13 Self Tapping Screw S8025 12 1 18 Meter Guard S10509 60 1 Shunt Not Illustrated See P 107 G 1 02 27 2001 P 107 L WIRE FEED SPEED METER VOLTMETER KIT P 107 L Indicates a Change This Printing ITEM DESCRIPTION PART NO 6789 Meter Kit Includes K207 1 1 Meter Housing L4753 1 2 Meter Panel M11487 1 3 Wire Feed Speed Meter M12653 1 1 4 Voltmeter M10486 3 1 5 Polarity Switch T13111 1 6 Polarity Switch Plate T13096 1 7 Toggle Switch T13381 1 8 Switch Plate T13096 1 1 13 Insulated Meter Shield M12663 0 1 14 P C Boar
82. 7 gt gt 683 Connector A 4 gt gt 632 2 gt gt 682 Jumper connector is removed amp connector 22 AS gt gt 634 1245 gt 536 plugged into optional variable voltage 524 power source board 525A NA an 6573 1 2 4 Terminal A strip Quick connect f i terminals 7 amp 32A voltage 2 4 31 32 21 75 76 77 GND 10 connect aux trigger al Eje e HL ETAG i 0 A ak 7 Bead pins on AS bottom of board 90No It is not accurate for all pecific diagram for a par y this manual The s NOTE This diagram is for reference machines covered b ticular code is paste panels If the dia iz to wire feed unit e enclosure Department Control cable control Wire feed motor Thermal circuit breaker Power input cable 2 from power source Wire feed amp LM speed rige 634 ra 4 SE 632 76 5 amp circuit breaker L Tee c 32A 32 A Power source output rheostat 2 536 OFF Interlock switch 1 Direction of wire feed switch Bolted connection d inside the machine on one of th gram is illegible write to the Service for a replacement Give the welder code number Connection box GND stud gt 524 5 voltage boards 528 Output connector E Gun trigger Electrical symbols per E 15
83. Air Line Connector Not Illustrated T14390 2 1 X 0 This part is obsolete and no longer available 12 20 2001 P 107 T P 107 T UNDERCARRIAGE K163 Standard with LN 6S LN 6SE LN 8S LN 8SE LN 9S and LN 9SE For optional K163 use parts marked X in Column 1 For LN 6S 6SE 8S 8SE 9S and parts marked X in Column 2 Indicates a Change This Printing ITEM DESCRIPTION PART NO 1 2 3 4 5 6 7 8 9 Undercarriage Includes K163 1 X Undercarriage Includes Standard Equip 1 X 2 Handle M10469 1 1 XX 3 Casters S11124 2 XIX 4 Base Platform Type Discontinued L4688 1 4 Base Open Frame Type L5239 1 X X 6 Wheels 13127 2 7 M10470 1 XX 12 Flux Tank Support S12737 3 x 10 22 97 NOTES P 107 V a P 107 V a MECHANIZED TRAVEL POWER PACK K161 G1429 10 23 81N 05 10 2005 P 107 V b P 107 V b Indicates a Change This Printing Use Parts Marked X in Column 1 for Code 6801 Use Parts Marked X in Column 2 for Code 7627 ITEM DESCRIPTION PART NO QTY 1 2 3 671819 Mechanized Travel Power Pack Includes K161 1 X X 1 Case Welded Assembly M9734 1 2 Assembly Includes
84. All Models eese ee eene aaa P 110 D D 1 LN 8F General Assembly Below Code 7575 Only P 110 E E 1 LN 8F General Assembly amp Instrument Panel Above Code 7575 Only P 110 F F 1 G G 1 Wire Drive Motor and Gear BOX eee eee eese eene R P 107 F 2 F 3 Wire Drive Mechani sM www een prima P 107 G G 1 K165 Ammeter Voltmeter Kit Below Code 7575 Only P 107 J K207 Wire Feed Speed Meter Voltmeter Kit Below Code 7575 Only P 107 L Input Cable and Extension LN 8SE and NE Cable P 107 M 50 and 60 Wire Reel Support aa nennen nen 107 1 K377 Stand Assembly for 204 P 125 N N 1 K378 Stand Assembly for 14 Pound Reel P 125 0 O 1 Wire Reel sss o qusan ga nen ee eng P 107 P Hand Crank Assembly usuarias I E P 107 R Flux Tank LN 8S and 856 o aa Bess ah en nina P 107 S S 1 Undercarriage K163 Standard on LN 8S and 8S
85. Assembly 3 32 Electrode K116 3 32 1 X X 1 Nozzle Includes M11475 120 1 X X 1 Nozzle Includes M11475 3 32 1 1 Nozzle Liner Tight Wound Steel Spring T12931 8 KP2095 7 1 Xie X 1A Nozzle Liner Tight Wound Steel Spring T12931 6 0 1 XX 1B Nozzle Insert T12576 3 KP2094 3 1 X X 1B Nozzle Insert T12576 1 KP2094 1 1 1 Nozzle Insert Retainer T12977 2 1 X X X X 1D Liner Locking Screw T12932 2 1 X X X X 2 Switch Housing Clamp S12339 1 1 X X X X Handle M10102 1 3 Handle M10102 1 1 e XIX 4 15 Conductor Cable Includes L5728 5 1 X X X X 4 15 Conductor Cable Includes L5728 10 1 X X X X 4 10 Conductor Cable Includes L4230 10 1 XX 4 10 Conductor Cable Includes L5728 10 1 e X X 4A Handle Wire Feeder End M14048 1 X X X X 4B Connector Wire Feeder End S12801 4 1 X X X X 4C Connector Gun End S12802 4 1 XX 4C Connector Gun End S12802 13 1 eje XX 4D Clamping Tube Both Ends S7748 40 2 X XXX 5 8 32 x 1 4 Pan Head Screw CF000049 4 XX XX 6 Socket Head Screw S11604 9 2 XX XX 7 Handle amp Control Cable Assembly 15 Length L5734 15 0 1 X X X X 7 Handle amp Control Cable Assembly 10 Length L4189 10 1 XX 7 Handle 8 Control Cable Assembly 10 Length L5734 10 1 XX Assembly Parts See P 103 H 1 XIX 8 Spatter Shield T12027 1 X X X X 9 Snap Ring S9776 7 1 X X X X 10 Clamp S11598 1 1 XX 10 Clamp S15921 2 1 XX 11 Socket Head Cap Screw T9447 9 1 X X
86. B Connection of LN 8 to an Idealarc R3S 400 600 or 800 without LVC Discontinued N E 9 To LN 8 input cable plug LN 8 Control cable Electrode cable to wire feed unit NB To work Negative Positive Q Q Above diagram shows electrode connected for positive polari ty To change polarity turn power off reverse the electrode and work leads at the power source and reverse the control switch at the power source Power source Tape up bolted connection Connect the LN 8 control cable ground lead to the frame ter minal marked 777 near the power source terminal strip or to an unpainted frame screw The power source must be ground ed properly 90No N A N B N C N D N D N E On earlier R3S 400 600 amp 800 machines 67 amp 1 terminals were also on the terminal strip Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Extend lead 21 using 14 or larger insulated wire physically suit able for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience this extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 8 m
87. BLESHOOTING 1 No control of power a DC 600 or R3S power source output source toggle switch not set to remote Set power source per its instruction manual b Defective K317 relay replace relay Defective wire feeder con trol rheostat Refer to oper ating manual e 2 Poor bead shape or arc a Mode switch in wrong response when using position on Dual Process DC 600 power source Contactor Kit or on welder Place in correct position b Defective K317 relay replace relay 3 Poor starting when a Improper connection on using DC 600 below power source terminals N Code 8200 P and S Refer to connec tion diagram to connect properly November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation OPTIONAL FEATURES CONT D Sec K2 5 19 File as Sec N3 5 2 in IM 294 K318 DUAL PROCESS CONTACTOR KIT With Polarity Change The dual process contactor kit is a control box transfer device that permits connection of two wire feeders to a sin gle power source and enables each wire feeder to weld at a different procedure and polarity without changing any dials or switches Simply actuating the gun trigger of the desired wire feeder turns the unit on selects the polarity and sets the complete procedure including power source output level When used with a DC 600 the wire feeders can also be set for different
88. Contactor Parts See P 28 H NVR Coil See Below 1 20 Relays and Mounting Panel Includes S10831 1 0 1 Pilot Relay 510957 0 1 Full Field Relay S10834 1 1 21 Capacitor 111079 1 23 T10728 17 1 24 Hex Head Screw 1 2 13 x 75 2 X X X 25 Stud T6931 3 2 26 Hex Jam Nut 1 2 13 8 27 Lock Washer E106A 5 2 28 Flat Washer S9262 1 4 X X X 29 Insulating Washer S10773 9 2 30 Insulating Panel 114373 2 31 Connecting Strap T8141 2 32 Flanged Nut T3960 2 33 Self Tapping Screw S8025 65 2 34 lnsulating Tube T14374 2 38 Equipment Lead 13469 1 39 Power Source Lead S13470 1 X X X Machine Item 19 Assembly No Voltage Hertz Item 3 Item 7 NVR Coil L4276 1 220 440 60 S10404 60 0 S13000 1 0 S2 7 L4276 2 220 440 60 S10404 61 S13000 2 S2 7 L4276 3 550 60 S10404 61 S13000 3 S4 3 L4276 4 415 50 S10404 61 S13000 4 S15 3 L4276 5 380 50 S10404 61 S13000 5 S13A 2 0 L4276 6 220 440 50 S10404 61 S13000 2 S2A 4 0 L4383 1 or 1A 230 460 60 S10404 61 S13000 2 S2 7 L4383 2 or 2A 575 60 S10404 61 S13000 3 S4 3 L4383 3 or 3A 415 50 S10404 61 S13000 4 S15 3 L4383 4 or 4A 380 50 S10404 61 S13000 5 S13A 2 0 14383 5 or 5A 220 440 50 S10404 61 S13000 2 52 4 0 14383 6 or 6A 550 50 S10404 61 S13000 3 SAA 3 Stamped on Power Pack Contactor Kit Nameplate 01 28 2003 0 This part is obsolete and no longer available P 107 W 2 a P 107
89. ESCRIPTION PART NO 6 7 8 9 1 Instrument Panel Assembly See P 110 D 1 2 Potentiometer T10812 71 1 3 Potentiometer Insulation T12792 1 2 4 Dial Plate Constant Voltage Below Code 9900 M12229 1 5 Dial Plate Variable Voltage LN 8S amp LN 8SE Only M12230 1 7 Nameplate Below Code 7900 S14629 1 7 Nameplate Above Code 7900 S16029 1 10 Base Assembly Below Code 7575 M11467 1 10 Base Assembly Code 7575 to 9100 5778 1 10 Base Assembly Code 9100 L5778 6 1 12 Wire Drive Motor 8 Gear Box Assembly See Model Index 1 14 Door Assembly Below Code 9000 M11490 1 14 Door Assembly Between Code 9000 amp 9900 M14850 1 1 14 Door Assembly Above Code 9900 M14850 3 1 15 Cover Assembly Below Code 9000 M12216 1 15 Cover Assembly Between Code 9000 amp 9900 M14851 1 1 15 Cover Assembly Above Code 9900 M14851 4 1 Door Bumper Above Code 9100 114882 1 17 Hinge Pin M8809 53 1 18 Self Tapping Screw S8025 68 2 19 Warning Decal 113470 1 21 Plug Button T13597 2 1 22 Trimmer PC Board amp Bracket Assembly Code 7575 thru 7900 Not Illustrated S15679 o 1 Trimmer PC Board S15680 1 24 Door Cover Panel Without Meters Only Below Code 9900 M11662 2 1 24 Door Cover Panel Without Meters Only Above Code 9900 M11662 3 1 26 Drive Roll Decal S14140 1 27 Optional Meter Kits Below Code 7575 Not Illustrated See P 107 J or L 1 27 Optional Meter Kits Above Code 7575 Not Illustrated S
90. GGER amp CONTROL CABLE ASSEMBLY 07 25 2006 NSS Not Sold Separately 3 P 202 C P 202 C Magnum 300 amp 400 GMAW Gun 05 03 2010 MAGNUM 300 4 400 GMAW GUN LINCOLN 5 P 202 C 1 Indicates a change this printing P 202 C 1 Use only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO aTY 1 2 34 5 6 7809 Gun amp Cable Assembly 300 Amp Specify cable length amp wire size K470 1 X 300 Amp Specify cable length amp wire size K2951 1 eX 400 Amp Specify cable length amp wire size K471 1 400 Amp Specify cable length amp wire size K541 1 400 Amp Specify cable length amp wire size K2952 1 X 1 Connector Assembly See P 202 C 2 1 X X 2A Gun Handle Left amp Right G1927 1 X X 2B Pan Head Screw for Handle S18825 1 3 XX 2C Handle Nut Knurled S18773 3 X X 3 Trigger Assembly Non Interlocking Standard S21002 1 X X 3 Trigger Assembly Interlocking Parts Order Only S20677 1 X X 4 Spring Boot Retainer Gun End Only S24719 1 X X 5 Connector Cover L7723 1 6 Nut Cable Handle S18690 1 X X 7 Gun Tube Assembly See Chart P 202 C 4 1 X 7 Gun Tube Assembly See Chart P 202 C 6 1 X 8 Tail Piece M15607 1 X X 9 Gas Plug Assembly S18695 1 X X 11 Slip on Nozzle Insulator See Cha
91. Gufde Moeel Assembly 1 ES when using any sti ckout extension Replace ftem 15 with item 18 Parts List P 165 tem PartNo Description Req 71160 Wheel Holder Asbiy 1 2 T9447 22 Socket Hd Screw 1 3 18862 GuideRole 1 4 T11692 Rubber Tire 1 6 S10868 16 Camp _____ 7 L3 8 T66752 _ Insulating Tube 2 9 510773 35 Insualting Washer 10 59262 27 PlainWasher 2 11 E106 A 1_ Lockwashr 2 12 10 24 x 7 8 Round Head Screw 2 13 T9078 3 WingScrew____ 1 114 S 11867 Guide Roll Holder 1 s EN N 15 Short Guide Roll Arm Long Guide Roll Arm The Lincoln Electric Company Cleveland Ohio 44117 1199 Maintenance SEC K6 1 WIRE DRIVE AND CONTROLS MAINTENANCE Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment HIGH VOLTAGE Do not touch electrically hot parts can kill WARNING Turn off power source before installing or changing drive roll and or guide tubes Sec K6 1 1 Drive Rolls and Guide Tubes After every coil of wire inspect the drive rolls and guide tubes and clean as necessary The drive rolls can be brushed with a wire brush Do not use a solvent on the outside drive roll as it may wash the lubricant out of the drive roll bear ing The
92. ITION SAME POLARITY ON FEEDERS CONNECT POWER SOURCE OUTPUT STUD OF M QUIRED POLARITY TO OUTPUT STUD ON BACH OF THIS B R AMD COMMECT THE OTHER POWER SOURCE OGTPUT STUD TO WORK TRANSFER SWATCH 10 Bt IM UP POSITION OPPORTA POLARITY ON CONNECT NEGATIVE POWER SOURCE QUIPUY MTU to a Ferne STUD ANG CONNICT POSITIVE SOURCE OUTPUT STUD tQ e STUD CONNECT WORK CABLE TO OUTPUT STUB OM BACK OF THIS BOX SWITCH TO BEIN GOWN POSITION DUAL PROCESS CONTACTOR KIT M Closeup of controls for the K318 dual process contactor NOTE when used with a DC 600 each mode switch should be set in the proper position for the process being used K318 mode switches have no function with any other power source Assembly and Installation Sec K2 5 19 Continued Operation For DC 600 set the mode switch on the front of the power source to CV Innershield Set the mode switches on the kit to the position required by the process used on the wire feeder On all other power sources the mode switches have no effect Check that transfer switch on the dual process contactor kit is in the proper position When wire feeders are connected for opposite polarity operation wire feeder A will be negative polarity and B will be positive polarity The Lincoln Electric Company Cleveland Ohio 44117 1199 Codes Above 8020 Before welding actuate gun trigger once to i
93. Install the LN 8NE LN 8SE input cable and extension cables Sec K22 10 Electrical Installation 7 Install the power source where desired and connect it to input power lines per the operating manual shipped with the power source 8 Check whether a constant voltage or variable voltage power source is to be used Sec K2 3 1 9 Connect the input cable to the power source Set the wire feeder and power source for constant or variable voltage as Sec K2 3 2 10 Use the appropriate connection diagram for the power source being used Sec K2 3 3 Optional Feature Installation K261 amp K262 Wire Feed Speed Voltmeter Kits eee eee esent tete aa Sec K2 5 1 K165 Ammeter Voltmeter Kit Sec K2 5 2 K207 Wire Feed Speed Meter Voltmeter erento toten ente Sec K2 5 3 Auxiliary Equipment Contacts Sec K2 5 4 2 5 5 K161 Mechanized Travel Power Pack For K110 or Squirtmobile with 114 Submerged Arc Gun sirning isendeid
94. Kg wire coils from the mounting framework Install the spindle per the instructions shipped with the kit Adjust the brake tension screw see Sec K3 1 8 B on the spindle as needed When used with Readi Reels the K363 Readi Reel Adapter is required November 1990 Sec K2 5 10 Wire Reel Enclosure Door This door is standard on the LN 8NE with an enclosed wire reel mount and the LN 8SE machines It is optional for LN 8S and LN 8N The door kit M11514 includes a hinged door and a sliding bottom seal When installed the wire reel mounting becomes a completely enclosed housing Instructions are included in the kit Put the bottom seal panel in the forward Assembly and Installation Sec K2 5 10 Continued position when using 035 thru 1 16 0 9 thru 1 6 mm elec trode and in the rear position when using 5 64 thru 120 2 0 thru 3 0 mm electrode November 1990 LN 8N with K162 Spool Spindle Sec K2 5 11 K185 Voltage Indicator A rugged portable arc voltage monitoring device with High and Low warning lights which indicate when the welding voltage varies more than about 1 2 volt on either side of the value preset on the calibrated dial Covers a range of 12 to 60 volts DC only Valuable where arc volt age must be closely maintained Instructions are permanent ly on the back of the device May 1974 Sec K2 5 12 K 163 Undercarriage The undercar
95. L3524 1 1 X X Core and Coil Assembly M9017 1 X X Resistor S10404 15 1 Insulation T11134 1 1 X X Terminal Strip T10707 1 X X Condenser T11577 37 1 Rectifier Assembly S13707 1 5 Terminal Strip S8542 1 6 Number Plate T10726 60 1 7 Relay S22182 1 X X 8 Lead Grommet T9274 1 1 X 8 Lead Grommet T9274 2 1 X 9 Adapter Box Assembly Includes M11617 1 X X Amphenol Connector Next to Toggle Switch 12021 3 1 X X Toggle Switch T13083 1 Amphenol Connector Opposite Side of Box from Switch S12020 6 1 XIX 10 Connector T9639 2 1 13 1 8 Amp T10728 9 2 X X 14 Fuse Holder S10433 2 16 Nameplate M9730 1 X X 18 Front Panel S11344 1 23 Fuse Identification Sticker T12607 9 1 24 Insulation T11472 5 1 X X 25 Spacer S10040 33 1 26 Hex Head Screw 1 4 20x3 00 1 X X 27 Spacer 10040 34 1 X X 28 Wiring Diagram S13868 1 28 Wiring Diagram M20116 1 X 30 Relay 15122 10 1 X 33 Fuse T10728 10 2 X X 34 Fuse Identification Sticker T12607 10 1 X X Specify Cable Length 05 10 2005 P 107 W P 107 W POWER PACK CONTACTOR KIT K124 and K130
96. NDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code
97. R3S 250 and R3S 325 Tape up bolted connection Power source EE To control box Control cable Electrode cable to LN 8 or NA 3 automatic shunt N B work Above diagram shows electrode connected positive To change polarity reverse the electrode and work leads at the power source N A Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded If optional solid state motor generator field control is not used tape up separately the B and C leads from the control cable Also connect a jumper from 2 to 24 on the power source terminal strip Bolt and tape connection If using an older control cable connect lead 75 to lead 75 of field control connect lead 76 to lead 76 of field control connect lead 77 to lead 77 of field control Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Extend lead 21 using 14 or larger insulated wire physically suitable for the installation An 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically sepa rate from the welding work lead circuit and connection For convenience this extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the
98. RAM uonoauuoo enoes 10 dujs EUIWJEJ ey Jesu pnis Jo Aq 25002 Jo BONOS J mod oj peaj ay 1o uuoo 8 pea uo dn dins ay uo eANoadsal O 3oed Jemod eu pue y ze LE spee jeuuoo pue ZE LE seu JOJDEJUOO 10 80JNOS Jamod oup uono auuoo e9ino eJnoes 190 JO dins EUILJG SUI Jesu pnis Jo sueeu Aq 14 JOJOEJUCO JO 8OJNOS JoMod etj JO eure eu O oed 1 eu 193uuoo p pue speo uo sBn ey dins ey uo y EUILJGJ 0 Jamod y pe JOBUUOD digs eure au uo yoed Woy pue j2ouuoo EUIS ou Ing pue 26716 SEY 1 JOJOEJUOO 10 S91NOS 18MOd DU J Butsnou Aejes ey uo adde sequinu Aue oj Jou pue Ajuo 0 sjequinu s u duis jeuiuuej ay uo ON SY oi pejoeuuoo aq JSNW speej p AYM pai au poq uogejedo 06 104 Y diis be Jojoeyoo JO e21nos OL ze a ZH 09 104 pea pes uo ede if HOLSISJU cE syun Jeipree uo esn jou snj dwe O i m gt gt
99. RETURN TO MAIN MENU IM274 A SEMIAUTOMATIC WIRE FEEDER June 2010 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL 180 9001 ao mm SS 10 MN lesigi ra Inc ABS Quality Eval to ISO 9001 Rex CERTIFICATE NUMBER 30273 LI NCOLN Copyright Lincoln Global Inc e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN A
100. Screw T9447 9 1 X 8 Contact Tip 5 64 Electrode Length 1 1 8 Note 1 amp 2 KP2100 4 As Req d X X 8 Contact Tip 3 32 Electrode Length 1 1 8 Note 1 amp 2 KP2100 3 As Req d X X 8 Contact Tip 068 amp 072 Electrode Length 1 1 8 Note1 amp 2 KP2100 1 As Req d X X 8 Contact Tip 062 Electrode Length 1 1 8 Note 2 KP2100 2 As Regd X X 10 Nozzle Includes M11476 KP1909 1 1 X X 10A Nozzle Liner Tight Wound Steel Spring T12931 4 KP2095 4 1 X X 10B Nozzle Insert T12576 2 KP2094 2 1 X X 10C Nozzle Insert Retainer T12977 1 1 X X 10D Liner Locking Screw T12932 1 1 X X 11 Trigger amp Control Cable Assembly M12462 1 X X Assembly Parts See P 103 K 1 X X 12 Clamp S15922 1 1 eX 12 Clamp S12339 1 X 13 Insulated Guide 2 3 4 Electrical Stickout Optional t Not Shown T12315 1 X X 13 Insulated Guide 2 00 Electrical Stickout Optional Not Shown S17217 1 1 X X 14 Heat Shield Assembly S13037 1 X X 15 Thread Protector 3 4 to 1 1 2 Stickout T12313 KP2089 1 1 X X 16 8 32 x 1 1 2 Round Head Screw CF000119 4 XX 17 Lock Washer T9695 3 2 XX 18 8 32 Hex Nut CF000042 2 XX Adapter Kit to use K126 with MN 1 or ML 3 M10682 0 1 X X Adapter Kit to use K126 with ML 2 512967 0 1 X X Specify Length 15 or 10 as appropriate K126 SQUIRTGUN amp CABLE 08 28 2007 This part is obsolete and no longer available LINCOLN P 103 K P 103 K Trigger amp Control Cable Assembly 07
101. Slip the roller guide down until the two small rollers touch the vertical plate Lock it in position The noz zle flux cone should never drag on the vertical plate when welding The roller guides and rear wheel should be parallel to the travel unit drive wheel If the fillet angle varies from one weld to another readjustment of the roller guide may be necessary For example assume the Fillet Guide was adjusted for an angle of 90 If the fillet angle of the next weld is 95 the cone may drag on the vertical plate Readjust the roller guide e Recheck the electrode alignment after tightening the guides and before making the welds When welding apply slight pressure down and forward on the gun This insures contact of guide wheels and the drive wheel with the plates November 1990 P 165 K 110 Mechanized Hand Travel Unit FIGURE 600 A GUN WITHOUT EXTENDED STICKOQT FIGURE 2 600 A GUN WITH EXTENDED STICKOUT If the rear wheel must be clamped the extreme forward position it ts necessary to Insulate between the hose clamp 5 the allen screw which 45 under the actuating lever A piece of duro paper severs thicknesses of Friction tape will do x 9715 8 vertical Plate 2 M x ee s eee e Posi tion e A gt E 5 Pogj sion ge Pog ti on R Nsttckout Extension Im 9715 A__Rear wheel Assembly 9715 8 _
102. T9447 9 1 XIX e e 4 Socket Head Cap Screw T14438 1 X X 5 Trigger and Control Cable Assembly M12462 15 1 X X XX Assembly Parts See P 103 K 6 8 32 x 1 4 Pan Head Screw CF000148 4 XX XX 7 Spatter Shield T12027 1 X XXX 8 Retaining Ring S9776 7 1 X X XX 9 Clamp S11598 1 9 Clamp S15921 2 1 X X 10 Conductor Cable Includes L5728 7 1 X 10 Conductor Cable Includes L4230 7 1 X 10 Conductor Cable Includes L4230 1 1 X 10 Conductor Cable Includes 350 Amp L5728 1 0 1 eX 10 Conductor Cable Includes 500 Amp L6250 4 1 e 9 X 10A Handle and Stiffener Wire Feeder End M14048 1 X X 10A Handle and Stiffener Wire Feeder End M14050 1 1 XX 10B Connector Wire Feeder End S12801 6 X X 10B Connector Wire Feeder End 350 Amp S12801 1 0 10 Connector Wire Feeder End 500 Amp S12801 9 10C Connector Gun End 350 Amp S12802 11 X 10C Connector Gun End 500 Amp S12802 16 X 10C Connector Gun End S12802 6 10C Connector Gun End S12802 1 X 10C Connector Gun End S12802 14 X 10D Clamping Tube Both Ends All Except 500A 57748 40 2 X XXX 10D Clamping Tube Both Ends 500A Only S16997 2 11 Cable Liner For K112 1 16 Electrode 350 Amp Only 512898 5 64 0 1 X Adapter Kit to use Squirtguns K113 with MN 1 and MN 3 Not Illustrated M10682 o 1 X Adapter Kit to use Squirtguns K113 with ML 2 Not Illustrated S12967 0 1 X X
103. UOA ejgeueA iS lt pieog 8 UNS 1 gt a H4 eno j Er 7 lt lt 3 Y IEJSOSLU 269 10128uu05 v paads yg ypequunq uondo y parowa 1 JOJDBUUG Jadwnp sunos Jemod pebBnid Joj2euuoo pue SI 1O158uuoo Jedunp M 14679 M 14680 Wiring Diagram The Lincoln Electric Company Cleveland Ohio 44117 LN 8N LN 8S OPERATING SCHEMATIC All Models 1 quinu ay juauw39e das 20 Juswpedag BOMBS ay ajqiG2j sI ay sjaued ainsojoua 24 40 uo dy pajsed s apo JEJNI UBd e ojjioads y siyy Aq 40 9181n22 JOU 3 luo 5u 19191 101 8 we4 eIp SIUL 3 LON Jequinu epoo e BUIAEU sjouoo jo slu uoduJo2 eui Moys JOU siy elejdwos e jo eBueyo pieoq p luud uo Jo sjueuodujoo 5 pieog O d uo 1ou slusuoduuoo CLOEL W 0062 4 4 LGCCL W WVUDVIA 4 4 Mojeq ay weep ajelldoldde ay 1sanba sapos
104. WAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 h To avoid scalding do not remove the not remove th powered equipment A i y en pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated 3 areas or vent the engine exhaust fumes GR outdoors ELECTRIC AND MAGNETIC FIELDS SN may be dangerous 2 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 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled f
105. X X 5 Plain Washer 1 38 O D S9262 14 1 5 Plain Washer 1 50 O D S9262 119 1 X 7 Insulator Bushing T14816 1 X X 8 Insulating Washer S10773 52 1 X X 9 Wire Reel Shaft Assembly 516253 1 X X 9 Wire Reel Shaft Assembly 515492 1 x 10 Roll Pin T9967 9 1 X X X 11 Pull Knob S11038 1 si LN 6 and LN 7 welders built before November 1972 did not have the adjustable brake Item 4 If a shaft or fixed brake assembly is needed order the M12460 Assembly 4 19 2000 P 107 R P 107 R HAND CRANK ASSEMBLY LN 6 LN 7 LN 8 and LN 9 L4703 For All LN 6 LN 7 LN 8S 8N 8SE LN 9S 9N 9SE 9NE 9NH and LN 22 use Column 1 For LN 8F LN 9F and LN 9FH use Column 2 Indicates a Change This Printing For SP 200 use Column 3 ITEM DESCRIPTION PART 6 7 8 9 Hand Crank Assembly Includes 14703 0 1 1 Plain Washer S9262 120 1 2 Hex head Screw 3 8 16 x 50 1 3 Bracket Assembly M10965 0 1 4 Lever Arm Stop pin T9967 4 1 5 Drive Screw S8025 7 2 6 Tension Spring 11514 1 7 Guide Tube S13686 1 8 Spacer Washer S9262 56 1 9 Conductor Block S13687 1 10 Hex head Screw 1 2 13 x 75 1 11 Shaft T12650 1 1 12 Roll Pin T9967 31 1 13 Drive Roll S12805 1 14 Conical Spring T12648 1 15 Idle Roll 1 16 thru 120 T12556 4 1 17 Incoming Guide Tube T12654 1 18 Retaining Ring S9776 1 1 19 Flat Head Screw 5 16 18 x 1 25 1 20 Handle 513397 1 21 Cr
106. ail et de la terre Ber hren Sie keine stromf hrenden Telle oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolleren Sie sich von den Elektroden und dem Erdboden e Nio toque partes el tricas e electrodos com a pele ou roupa molhada isole se da e terra ATENC O Japanese te BIR W hO BS 7 Atrei NTOSMIELTFAU e BRAZ WU DEMA BHR t B M bm sl FERME SUSE Xe 2 Fe WU 84x e 2719 BSA OMAL o ja aa YO A a 0 ji i edy ZU dal Di du e Ye READ AND UNDERSTAND THE MANUFACTURER 5 INSTRUCT ION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S 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 e Keep flammable materials away Mantenga ef material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sle brennbarres Material Mantenha Inflam veis bem guardados e x e u 07 f TOHI tR 2BNRELTWZEWZE A 5 Pi ph is RET EM ess Aria a gl Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votr
107. amp SP170T Connector Assembly Includes Set Screw O Ring 2 required Socket Key Wrench Gun Control Cable Assembly S18653 2 S11604 51 T13483 8 T11563 4 S18845 M18003 K466 5 Connector Kit For L Tec Adapted Feeders Connector Assembly L Tec Includes Set Screw O Ring 2 required Socket Key Wrench Gun Control Assembly L Tec S20044 S11604 51 T13483 8 11563 4 18845 M16520 K466 10 Connector Kit Lincoln 10 Series Connector Assembly Includes Set Screw O Ring 2 required Socket Key Wrench Gun Control Cable MAGNUM 300 4 400 GMAW GUN LINCOLN 5 S18653 S11604 51 T13483 8 T11563 4 S18845 M15608 05 03 2010 P 202 C 6 PARTS P 202 C 6 Contact Tips Gas Diffuser 250A 350A CHARTA Part Number Industry Ref KP2744 035 or KP2744 035 B100 KP2744 045 or KP2744 045 B100 KP2744 052 or KP2744 052 B100 KP2744 116 or KP2744 116 B100 KP2744 564 or KP2744 564 B100 English Wire Size CHART C 250 350 450 Amp Part Number Industry Ref Cable Liner For Steel Metric Wire Size For 15 ft 4 5 m and less Trim to Fit 450A 550A KP2745 035 or KP2745 035 B100 KP2745 045 or KP2745 045 B100 KP2745 052 or KP2745 052 B100 KP2745 116 or KP2745 116 B100 KP2745 564 or KP2745 564 B100 44 3545 15 KP44 116 15 KP44 564 15 KP42 25 15 Metric Wire Size English Wire Size 035 045 052 1 16 1 16 5 64 025 030
108. ank Arm Assembly 13392 1 22 Lever Arm Assembly S13404 1 23 Retaining Ring S9776 3 1 24 Fiber Pin T8433 1 25 Socket Head Cap Screw T9447 10 0 2 26 Set Screw S11604 11 1 27 Hex Head Screw 3 8 16 x 1 25 2 Insulating Tube T7305 4 2 Insulating Washer S10773 19 2 Plain Washer S9262 120 2 Lock Washer E106A 4 2 Hex Nut 3 8 16 2 Insulating Pad T8477 12 1 0 This part is obsolete and no longer available 01 30 2003 P 107 S P 107 S FLUX TANK LN 6 LN 7 LN 8 and LN 9 BA gt gt LA less mi m DIAN reat FU y EB 1 4695 4 9 19 80 3 15 82 107 5 1 107 5 1 Use Column 1 for Flux Tanks with Safety Valve on Outlet Assembly Use Column 2 for Flux Tanks with Safety Valve on Pressure Regulator Indicates a Change This Printing Use Column 3 for Flux Tanks used on Welding Station t ITEM DESCRIPTION PART NO QTY 1 2 3 4 6 7 8 9 Flux Tank Assembly Includes K320 1 X Flux Tank Assembly Includes L4695 4 1 Flux Tank Assembly Includes L4695 2 1 X 1 Flux Tank G1204 1 X 1 Flux Tank G1204 1 1 2 T11182 1 X X X 3 Tank Cover S11461 1 XXX 4 Instrument Mounting Bracket S12741 1 5 Hex Head Screw 1 2 13 x 1 25 2 XXX 6 Lock Washe
109. ara tor removes some of the alloying elements from these fluxes thus changing their characteristics K310 Screen Optional The unit was designed to fit the top of either the standard fill funnel of a continuous flux feed system or a K58 magnetic separator The unit has a steel screen with 065 to 075 1 6 to 1 9 mm openings and an air vibrator attached to the frame The vibrator can be used with air line pressures ranging from 20 psi thru 100 psi 137 thru 689 kPa For ease of handling the user should connect the incom ing air line to the 1 8 3 2 mm pipe elbow with the aid of a fast disconnect type air coupling It is very important that reclaimed flux to be used in the continuous flux feeding system be passed through the K310 screen or its equivalent November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 AAWARNING Do not touch electrically live parts or electrode with skin or wet clothing Always wear dry insulating gloves Insulate yourself from work and jens ground can kill Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone FUMES AND GASES can be dangerous Keep flammable material away Do not weld upon containers which have held combustibles WELDING SPARKS can cause fire or explosion Wear eye ear and body protection ARC RAYS can burn Sec K3 2 3 File as Sec N4 4 15 in IM
110. c K2 5 7 K202 Burnback Kit This kit is useful to help prevent the electrode from sticking in the crater at the end of the weld in two types of welding applications K202 Kit P C Board The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation OPTIONAL FEATURES CONT D Sec K2 5 7 Continued 1 Welding with small diameter 035 thru 1 16 0 9 thru 1 6 mm wires at fast wire feed speed when there is a tendency for wire overrun 2 When the semiautomatic gun is mounted in a fixture or on the Squirtmobile in such a manner that it cannot be lifted from the work at the end of the weld The kit delays the dropout of the contactor allowing the electrode to burn back from the crater at the end of the weld The delay time is adjustable for optimum burnback for different wire sizes processes procedures etc Installation instructions are shipped in the kit November 1990 90No Sec K2 5 8 Mounting Platform LN 8 on Idealarc R3 This is a turntable type platform for mounting the LN 8 on the top of Idealarc R3S power sources Bolt the platform to the lift bail per instructions supplied with the platform August 1973 Sec K2 5 9 K162 Spindle for Mounting Readi Reels and 10 thru 30 Pound 4 5 thru 13 5 Kg Spools For use with K303 Wire Reel Stand To mount the spindle kit for 10 thru 30 pound 4 5 thru 13 5 Kg spools remove the shaft for the standard 50 60 pound 22 5 27 2
111. cket in position against the back of the wire drive unit c Replace and tighten the screws The long screw goes into the top hole LN 8N Meters Optional 2 LN 8NE wire feed unit wire reel with hand crank and extension cables are shipped separately Install per Sec K2 2 10 To convert LN 8N to LN 8NE order the appropriate equipment indicated in the photo above 90No 3 LN 8F is designed for mounting on a boom or other fix as appropriate to the installation It consists only of a wire feed unit a control box and 15 4 5 m extension cable assembly to join the two units See Sec K2 2 2 for installation instructions LN 8F Meters Optional 4 LN 8S is shipped with the wire reel mount and flux tank installed on the undercarriage See Sec K2 2 1 for mounting the wire feed unit to the wire reel The four basic sections wire feed unit flux tank reel mount and undercarriage can be separated and mounted where most convenient for specific application needs LN 8S Meters Optional Assembly and Installation Sec K2 2 1 Continued 5 LN 8SE is shipped with the wire reel mount including door and hand crank and flux tank installed on the undercarriage Bolt the handle to the front of the under carriage base Place the wire feed unit near the welding location and install t
112. cludes items 2 4 through 9 and 13 For LN 7 K376 or K445 Reel S14543 must also be installed when a K1898 1 door is to be installed 0 This part is obsolete and no longer available 08 25 2009 P 125 N P 125 N STAND ASSEMBLY FOR READI REEL K377 CURRENT MOLDED OBSOLETE ALUMINUM PLASTIC SPINDLE ASSEMBLY 14 WIRE WHEEL L SUPPORT WIRE WHEEL SUPPORT OBSOLETE MOLDED PLASTIC SPINDLE ASSEMBLY 5 LU WIRE WHEEL SUPPORT L6940 12 19 85G 11 25 97 P 125 N 1 P 125 N 1 Indicates a Change This Printing For Obsolete Molded Plastic Spindle Assembly Use Column 1 For Obsolete Aluminum Spindle Assembly Use Column 2 For Current Molded Plastic Assembly Use Column 3 ITEM DESCRIPTION PART NO QTY 121314 516 7 8 9 1 Wire Reel Support Assembly L6831 3 1 2 Wire Reel Shaft Assembly M14511 1 X 2 Spindle Assembly M14935 1 X X 3 Readi Reel Adapter K363 P 1 4 Insulating Washer S10773 52 1 5 Insulator Bushing T14816 1 X 5 Bushing T14844 1 X 6 Brake Disc S
113. collapsing of hose can be felt Shake the hose and feel for slag at this the hose point Blow out hose with air if necessary Flux tank outlet may be clogged If there is no flux in the hose check the tank outlet for large pieces of slag or paper Pressure in the tank may be set Set pressure regulator for 30lbs sq in 206 improperly Set pressure for 45lbs sq in 310KPa with 1 2 12 1 0 hose and 55lbs sq 379KPa with 3 8 37 1 0 hose when using a gun cable extension assembly LN 8NE LN 8SE Check screen 29 in fitting 28 at top of flux tank See Sec K7 3 Page T If screen is clogged tank may not have proper pressure even when gauge reads O K Tanks manufactured prior to 1 80 have screen at bottom of tank 3 Excessive air blow and uneven flux Tank may be almost empty May look Refill the tank flow from the gun like the tank is full at the sides but it will be down to the bottom in the cen ter Flux may be fallingaway from the Alter procedure or make a flux dam weld faster than it is being fed Pressure in the tank may be too high Set pressure regulator as specified in 2 4 Flux in tank gets wet There may be too much water in the If too much water goes into the water disposal sys air line tem the overflow goes into the tank It is possible to get this much water from air lines when first starting in the moming Blow out air lines before connecting them to the tank The
114. current flows Discharges slow Electrode is through free acceleration cold to work wheeling diode D 7 on capacitor C3 on control board control board Motor stops Resets slow acceleration circuit Unit ready for next weld NOTE 1 When Interlock is open NOTE 2 When Interlock is closed NOTE 3 3CR is not used on units with Code No 7926 and up October 1977 The Lincoln Electric Company Parts List Cleveland Ohio 44117 1199 SEC K7 1 PARTS LIST INDEX Squirtgun and Cable Assemblies Page No K112 and K113 Squirtguns and Cables P 103 C C 1 Gun Assembly Squirtguns K112 and K113 P 103 D D 1 K114 Squirtgun Cable mc P 103 E E 1 P 103 E 2 K115 Squirigun and Cab lt lt W POKO P 103 F F 1 K116 Squirtgun and Cable retenti ettet RA A Aa wd P 103 G G 1 K116 Squirtgun Handle and Control Cable eee u P 103 H H 1 K126 Squirtgun and Cable NENNT P 103 J J 1 Trigger and Control Cable Assembly acris l Aa P 103 K K 1 K470 and K471 Magnum Gun and Cable Assembly P 202 C C 1 C 2 C 3 C 4 C 5 C 6 LN 8 Wire Feeders and Options Wire Feed Unit Except LN 8P ses ken P 110 C C 1 Instrument Panel
115. d Clean per Sec K6 2 1 e Replace or reverse split drive roll type f Replace the electrode if it is rusty If conditions are extremely dirty or electrode is old solid wire only put a wiper on the wire before it enteres the guide tube Use a piece of cloth or felt saturated with Pyroil held around the wire with a light clamp g Replace nozzle liner h Replace the contact tip Gun cable dirty e Worn drive rolls Electrode rusty and or dirty g Worn nozzle liner h Partially flashed or melted con tact tip 2 Variable or hunting arc Contact tip worn or incorrect size b Worn or undersize work cables or poor work connections Loose electrode connections Replace contact tip b Inspect repair or replace as necessary c Be sure the following connections are tight electrode cable to wire feeder and power source work cable to power source and work gun cable to wire feeder contact block gun nozzle to body and contact tip to nozzle 3 Poor arc striking with sticking or blast offs weld porosity narrow and ropey looking bead or electrode stubbing into plate while welding See Sec K3 2 to Make Submerged Arc Welds S604 or Innershield Production Welding Guide N675 Improper procedures or tech niques 90No Maintenance The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K6 4 1 Contin
116. d When the LN 8SE with the 22 1 2 or 45 6 9 or 13 7 m extension is used and the flux hose is long set the air pressure at 45 psi 310 kPa for 1 2 12 mm I D hose and 55 psi 379 kPa for 3 8 9 5 mm I D hose Exact pressure is indicated on the pressure gage Air consumption is nor mally less than 1 5 cubic feet per minute of welding Connect the input air hose to the street elbow located at the right side of the flux tank A quick disconnect con nector should be installed between the elbow and the input hose The tank air system is equipped with a water and dirt sep arator Water separated from the input air feeds down through the long flux filled tube located at the input con nection It is exhausted from the system through the coiled tube below the flux tank There is always a small amount of air and possibly water coming out of the end of this tube November 1990 90No Sec K2 2 LN 8N and LN 8S Input Cable Installation The input cable consists of an electrode cable and multicon ductor control cable The control cable has a polarized plug on the wire feeder end To install 1 Connect the polarized plug of the control cable to the mating connector on the back of the wire feeder 2 Remove the screws holding the cable clamp located near the rear of the wire reel base Put the control cable and the electrode cable under the clamp and install the screws On cables with more than one electrode cable leave the j
117. d Insulation 15157 0 1 15 P C Board Assembly 515158 1 16 Tubing E2106 1 219 41 2 17 Lockwasher E106A 2 2 19 Meter Guard S10509 60 1 21 Calibration Tool 113660 1 O This part is obsolete and no longer available 01 22 2002 P 107 M INPUT CABLE AND EXTENSION CABLE ASSEMBLIES P 107 M Indicates a Change This Printing ITEM DESCRIPTION PART NO 6 7 8 9 LN 6 Power Input Cable Assembly Includes K164 1 Control Cable Assembly Includes L4700 B o 1 Amphenol Connector Female S12020 11 1 Amphenol Connector Male S12020 12 1 Amphenol Connector Clamp S12024 2 2 Electrode Cable Assembly L4700 C 1 LN 8 amp LN 9 Power Input Assembly Includes K196 1 Control Cable Assembly Includes L5027 B 1 Amphenol Connector Female 12020 8 1 Amphenol Connector Male 12024 2 1 Electrode Cable Assembly L5027 C 1 LN 6NE amp LN 6SE Extension Cable Assembly Includes M11518 1 Control Cable Assembly Includes M11517 1 Amphenol Connector Female 12020 11 1 Amphenol Connector Male 12023 3 1 Amphenol Connector Clamp 12024 2 2 Conductor Cable Assembly L4702 1 LN 8NE 8SE 9NE amp 9SE Extension Cable Assembly Includes M12220 1 Control Cable Assembly Includes 12219 1 Amphenol Connector Female S12020 8 1 Amphenol Connector Male S12023 2 1 Amphenol Connector Clamp S12024 2 2 Conductor Cable Assembly L4702 1 Flux Hose 22 1 2 Ft Req d For
118. d sharp corners b Keep the electrode cable straight as practical when welding or starting the electrode through cable c Do not allow dolly wheels or trucks to run over cables d Keep cable clean by following maintenance instruc tions e Use only clean rust free electrode f Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed General The LN 8 is used with various guns In all cases the gun is shipped connected to the cable ready to weld Use the gun recommended for the wire type solid or cored and size to be used Note The guns described below were available at the time this sheet was printed They may not be today See Lincoln Specification literature for up to date informa tion Gun Cable LN 8 to Gun Lay the cable out straight Insert the male end of the welding conductor cable into the brass block on the front of the LN 8 Make sure it is in all the way and tighten the locking screw with a 3 16 4 8mm Allen wrench Keep this connection clean and bright Connect the control cable polarized plug into the receptacle next to the cou pling Submerged Arc Guns For 1 16 1 6 mm wire use Squirtgun K112 For 5 64 2 0 mm wire use Squirtgun K113 5 64 For 3 32 2 4 mm wire use Squirtgun K114 also can be N gt K112 or K113 The Lincoln Electric Company Cleveland Ohio 44117 1199 used for 5 64 2 0 mm wire or K113 3 32 The K1
119. d wire feed speed meter which operates while welding It normally reads amperes To read wire feed speed in in min set the toggle switch next to the meter for Hi or Low speed range as desired and press the spring loaded switch next to the meter Both kits include a voltmeter polarity switch and a Direct Work Lead Jack A 15 4 5 m lead with a jack plug on one end and an alligator clip on the other is included in the K262 kit and can be ordered as Part No 15636 for the K261 When this lead is plugged into the jack the normal voltmeter work sensing lead 21 in the input cable is dis connected from the circuit removing the work lead and its connection to work from the voltmeter reading The volt meter then reads between the shunt in the wire feeder and the alligator clip connection usually on the work It is not necessary to employ the Direct Work Lead if 21 lead is extended directly to the work per the connection dia grams in Sec K2 3 3 dated after 6 15 79A K 261 Analog Lead Optional 90No K262 Electronic The K261 kit includes an analog voltmeter which indicates voltage directly on a scale The K262 kit includes an electronic voltmeter with indica tor lights A green light glows when the actual voliage matches the voltage preset on the voltmeter dial Either red light glows when the voltage is higher or lower than the preset voltage The wire feeder must be recalibrated if the motor
120. designer to fit the requirements of the specific installation When designing this system minimize bends in the wire and the force required to pull the electrode from the reel Pulling the electrode through a tube may cause the electrode to spiral as it leaves the gun For best results use eyelets spaced far enough away The Lincoln Electric Company Cleveland Ohio 44117 1199 SEC K2 2 MECHANICAL INSTALLATION CONTINUED 00000000 Assembly and Installation z m Wire Feed Mechanism set for 3 32 2 4 mm electrode diameter Sec K2 2 2 Continued from the beam and far enough apart to let the wire spiral naturally as it goes into the ingoing guide of the wire drive mechanism CAUTION Since the electrode is at welding potential when welding the wire and reel mounting must be insulated from the boom or fixture November 1990 Sec K2 2 3 Wire Feed Rolls and Guide Tube Kits WARNING Turn off power source before installing or changing drive roll and or guide tubes The drive rolls and guide tube kits are ordered separately Install these parts per the following instructions 1 2 3 4 96Au Loosen idle roll spring pressure screw 1 Remove clamping collar 2 from the drive shaft Install drive roll 3 and replace clamping collar 2 Tighten screw 4 Remove idle roll shaft screw 5 install idle roll 6 Replace screw and tighten Remove the large ingoing guide 7 from rear brass bloc
121. drive rolls and guide tubes are stamped with the wire size for which they are designed If a wire size other than that stamped on the drive roll is to be used the drive rolls and guide tubes may have to be changed See the parts List Sec K7 3 page G in the back of this manual for the neces sary parts The inner drive rolls for 068 thru 120 1 7 thru 3 0 mm wire have a double set of teeth so they can be reversed for additional life Between the two knurled rolls is a shim washer which limits the damage to the wire to a minimum should wire feeding problems occur When drive rolls are interchanged leave the three socket head screws of the roll assembly loose until it is re assembled on the drive shaft Then tighten all three Be sure the roll faces and spacer faces are thoroughly cleaned before re assembly Drive rolls for 1 6 1 6 mm and smaller wire have no teeth They are not reversible November 1990 Sec K6 1 2 Wire Drive Motor and Gear Box Every year examine the gear box Coat the gear teeth with moly disulfide filled grease Do not use graphite grease Check the motor brushes Replace if they are worn down to 1 4 6 4 mm or less When ordering feed motor brushes give all information from the motor nameplate November 1990 90No Sec K6 1 3 Wire Reel Assembly For 50 amp 60 Pound 22 7 amp 27 2 Kg Coils To prolong its life periodically coat the reel shaft with a thin layer of grease No maintenance
122. dures 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLI
123. e brass block on the hand crank assembly using the screw provided 4 Position the 22 1 2 or 45 6 9 or 13 7 m extension cable assembly so the polarized connector with the threads on its O D is at the wire reel mount Assembly and Installation K2 2 10 Continued 10 12 Connect the polarized connectors of the extension cable and input cable together Place both control and electrode cables of the input cable assembly under the clamp on the wire reel mount and tighten the screws Insert the connector on the electrode cable of the extension assembly into the brass block of the hand crank assembly and tighten with a 3 16 4 8 mm Allen wrench At the wire drive unit connect the polarized plug of the extension control cable into the mating recepta cle on the back of the wire drive unit Remove the ingoing guide tube from the rear brass block of the wire drive unit and plug the connector of the conductor cable into the brass block Tighten the locking screw with a 3 16 4 8 mm Allen wrench The guide tube removed is not used when the extension assembly is installed POLARIZED CONNECTOR INPUT CABLE ASSEMBLY BRASS HAND BASE BLOCK CRANK If using over 450 amperes connect a length of 1 0 cable between the brass block on the wire reel hous ing and copper strap on the rear brass block of the wire drive unit Tape this cable to the extension assembly Proper cable lengths are as follows 22 1 2 6 9 m
124. e corps e Tragen Sle Augen Ohren und K r perschutz e Use prote o para a vista ouvido 6 corpo e B BU HRSNMSRRHAR ex 19 Sol 5857 HESHIAE y due ule ue lso A 3 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 HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von SchwelBrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventila o e exhaustiio para remover fumo da zona respirat ria etai LAbosUi EA Feu TRS EW K fb A on e Y22749 SAR WAHAR SANAR 21 AA 290421 SZR gin OF Jamy dal cd hiso ja 5 Jaial ge gi
125. e or service this machine M14550 1 20 89B Assembly and Installation Sec K2 3 3 M K318 Dual Process Contactor Kit DC 400 CV 400 and CVI 500 Connection to LN 8 or LN 9 for Opposite Polarity Operation N B B Welder control cable 21 218 N C 93 ESO o 2 9999 70 1 21 q o_O EEE A E A E Sf 5 To negative To positive output stud on output stud on power source power source N A A Connect the control cable ground lead to the frame marked near To wire feeder the power source terminal strip or to an unpainted frame screw electrode negative The power source must be properly grounded N B B Extend lead 21A amp 21B using 14 or larger insulated wire physically N A N B N C N D N E suitable for the installation 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit amp connection For convenience these extended 21 amp 21B leads should be taped to the welding work lead Each lead must be connected directiy to the work amp leads must not be con nected together Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Bolt and tape connections ELECTRIC SHOCK Tape up separately can kill Put transfer switch in Opposite Polarity on Feeders position
126. ead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding lead circuit amp connection For convenience these extended 21A amp 21B leads should be taped to the welding work lead Each lead must be connected directly to the work amp leads must not be connected together N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N B Bolt and tape connections N C Tape up separately N D Puttransfer switch in Same polarity on feeders position N E Mode switches on contactor kit are not functional when used with the power source N F Connection shown for negative polarity For positive polarity reverse electrode and work cables connected to power source Output studs 90No N B B Welding lead stud on back of contactor kit Dual Process Contactor E Mola GE aa ee en N B A eno Wire feeder Electrode f wire feeder control cables control cable A cable To A wire feeder To B wire feeder For 50 HZ operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B WARNING Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts ELECTRIC SHOCK can kill Only qualified persons should install us
127. ec K3 1 1 Welding with a Constant Voltage Power Source eese eese ente ta aaa tonne Sec K3 1 2 Welding with a Constant Current Power Source eese eese eese eee tote tinent arte Sec K3 1 3 Linc Fill Long Stickout Welding Sec K3 1 4 Wire Reel Loading eee A IR kaa Awa as Sec K3 1 8 Flux Tank Loading TT Sec K3 1 10 For Innershield operating techniques and procedures request Innershield Production Welding Guide Bulletin N675 90No Index The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K3 Operating Instructions cont d Making Submerged Arc Welds Gun Operating Positions Squirtgun K114 a Sec K3 2 3 Fillet Guide Optional K70 cccsssssessssscsssssececesssssscecececssscssesnsesesosetesvsesossestsevsrsessesavsuseasosoneessescanan Sec K3 2 4 For additional submerged arc operating techniques request How to Make Submerged Arc Welds Bulletin 5604 Sec K6 Maintenance Wire Drive and Controls Drive Rolls and Guide T bes ei ehe Sec K6 1 1 Wire Drive Motor and Gear BOX l L S Su u away isuwa sassa Sec K6 1 2 Wire Reel rere ue ree 6 1 3 Control OR Sec K6 1 4 Circuit Protection A
128. ee P 110 A 29 Knob T10491 2 30 Potentiometer T10812 40 1 32 Grounding Lead Protector Assembly Below Code 7900 S15102 32 Grounding Lead Protector Assembly Above Code 7900 to 9100 S15102 3 1 33 Resistor S10404 75 1 Round Head Screw 10 24 x 5 00 1 Insulating Washer T4479 A 2 34 Reset Decal T13086 4 1 35 Resistance Coil Code 7900 to 9100 T14104 1 39 Roll Pin T9967 22 1 40 Warning Label M16196 1 41 Shunt Assembly M11502 1 Items Not Illustrated Collar Assembly Drive Roll Mounting T12341 1 Button Head Socket Screw Drive Roll Mounting T11551 6 1 Key Drive Roll Mounting M8776 31 1 Handle Optional S13863 1 07 19 2001 0 This part is obsolete and no longer available P 110 D P 110 D LN 8 INSTRUMENT PANEL ASSEMBLY All Models Except LN 8F Above Code 7575 NOTE Obtain both item number and complete description for parts listed Some older operating manuals were printed with item numbers which do not correspond with recent printings
129. el Below Code 9900 M11662 2 1 3 Door Cover Panel Above Code 9900 M11662 3 1 6 Instrument Panel Assembly See P 110 G 1 8 Resistor S10404 75 1 8 Round Head Screw 10 24 x 5 00 1 8 Insulation T4479 A 1 11 Nameplate Code 7575 thru 7900 M13126 1 11 Nameplate Above Code 7900 M13431 1 16 Interlock Switch T10800 20 1 17 Wire Direction Switch 1713495 1 18 Dial Plate M13110 1 19 Warning Plate Decal T13470 1 20 Potentiometer T10812 71 1 Knob T10491 1 21 Insulation T12792 1 2 22 Potentiometer T10812 40 1 Knob T10491 1 25 Circuit Breaker T12287 10 1 28 Terminal Strip Code 7575 thru 7900 S13323 2 1 28 Terminal Strip Above Code 7900 S13323 6 1 Number Plate Code 7575 thru 7900 T10726 113 9 1 Number Plate Above Code 7900 T10726 121 0 1 29 Optional Meter Kits See P 110 A 1 34 Reset Decal T13086 2 1 35 Grounding Lead Protector 15102 3 1 Items Not Illustrated Input Polarized Connector 12021 12 1 08 09 2001 Q This part is obsolete and no longer available P 110 G P 110 G LN 8F INSTRUMENT PANEL Above Code 7575 Only M13109 6 3 77B For codes 7575 thru 7900 use the parts marked X in column 1 For codes above 7900 use the parts marked X in column 2 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 1 2 34 5 6 7 89 Instrument Panel Assembly Inc
130. ent size and length per the following table between the To Work stud on the power source and the work Be sure the connection to the work makes tight metal to metal contact Copper Work Cable Length 100 45m 00 __0000 0000 Current Amps 60 Duty Cycle Two 000 CAUTION Never operate a Lincoln Squirt welder wire feeder with a power source that has a jumper from 2 to 4 on the terminal strip or with a power source without a contactor To do so would defeat the grounding lead protector circuit and could result in overheating of the electrical ground circuit to the wire feeder November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K2 3 3 A Assembly and Installation Connection of LN 8 to an Idealarc R3S 400 600 or 800 with LVC Discontinued c To optional R3S line voltage compensator Y To LN 8 o Input cable plug LN 8 Control cable Electrode cable to wire feed unit N B work Tape up bolted connection Above diagram shows electrode connected for positive polarity To change polarity turn power off reverse the electrode and work leads at the power source and reverse the Control Switch at the power source Connect the LN 8 control cable ground lead to the frame terminal marked 7 7 near the power source terminal strip or to an unpainted Sec K2 3 3
131. er kits which have a direct work lead jack 1 lead should be taped to the weiding work lead This 515293 1 25 80 The Lincoln Electric Company Assembly and Installation Cleveland Ohio 44117 1199 Sec K2 3 3 J Connection of LN 8 or LN 9 to DC 600 To LN 8 or LN 9 input cable plug Power source N G Control cable WARNING Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts ELECTRIC SHOCK Only qualified persons should can kill install use or service this machine Electrode cable to wire feed unit To work Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and position the switch on power source to proper polarity For optimum performance with the LN 9 DC 600 s with codes 8288 and above are preferred N B Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N C Extend lead 21 using 14 or larger insulated wire physically suitable for the installation An 516586 remote volt age sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically sepa rate from the welding work lead circuit and connection For convenience this extended 21 lead should be taped to the welding work lead This extended 21 lead connec
132. eter kits which have a direct work lead jack LN 8 leads A B amp C are taped up when R3S line voltage compensator is connected Arc voltage is controlled by the line voltage compensator rheostat There will be no adjustment of voltage by the LN 8 voltage control Older LN 8 control cables are tagged 475 76 and 77 instead of A B and C Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts ELECTRIC SHOCK Only qualified persons should can kill install use or service this machine 16026 4 20 79 On earlier R3S 400 400 600 amp 800 machines 67 amp 1 ter minals were also on the terminal strip Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Extend lead 21 using 14 or larger insulated wire physically suit able for the installation An S 16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience this extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 8 meter kits which have a direct work lead jack If using an older LN 8 control cable connect lead 475 to 475 on terminal stri
133. eui 0606 sepoo 104 Ajuo pue 0606 Sopoo uo pasn 1o SIS EN 0989 DOA Pe 109 H3AHO3SNVHUI 3S Id E Ef Ld G3vtsoo ACOP vel 01455 0494500 6019 93906 2080 Smis ADO veL 10496 90104019 9020 Q4mz0 y NOILOBLOHd LN3ISNVHL 1041 EHO 2119 daanos lt 020 9305 1020 Sunejado 0 EZ LSLS ees pieog Yoequung jeuondo 2o9Nz 1119 0159 9019 SI9SNZ 019 z feed si g 10 08uu00 pue SI YN 2010 POLO S8 ON Sein 1010 OL FOINGE 019 Gane 2012 HNS S son 03 41 1019 1 PRUCJ 52 a pisu paa N am 191289405 asado 801NOS 101905 gi Jamod x m lt lt 9 2 5 q ze YAMS ae pora 010 dure g 774 SEEM ES peieduun g 0 ua gt MN HUN JOU SI Stu USYM 8 1 ejejedo 7 2 al peal GND S OL 8ulj 510 JO JYUGU Ionuoo UNA jeuueu L pons 105 Buipunojb seo 85 NOTES The Lincoln Electric Company M 13352 Cleveland Ohio 44117 Wiring Diagram All Models Burnback To power source P C Board optional
134. f when installing the wire feeder WARNING Do not touch electrically live parts or electrode with skin or wet clothing Always wear dry insulating gloves Insulate yourself from work and ELECTRIC SHOCK ground can kill Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone FUMES AND GASES can be dangerous Keep flammable material away Do not weld upon containers which have held combustibles WELDING SPARKS can cause fire or explosion Wear eye ear and body protection ARC RAYS can burn Sec K2 3 1 Constant Voltage or Constant Current Use the type of power source required for the specific weld ing application A constant voltage power source is required for Innershield electrode and other open arc welding It is often preferred for small single pass submerged arc welds at fast travel speeds In the past a constant current power source was recom mended for most submerged arc welding CV Submerged Arc With the innovation of the new DC power sources a special mode CV Sub Arc is available and is preferred for most sub arc welding When shipped the LN 8N LN 8NE and LN 8F can only be used with a constant voltage power source These models 90No can be converted to weld with a constant current power source with installation of the proper parts See Sec K2 5 14 When shipped the LN 8S and LN 8SE welds with
135. he A O electrode termina or feeder need to employ the remote work lead accessory on LN 8 N A amp N C k terminal EE shunt or feeder Sec K2 3 3 F Etectrode N B cable to to work automatic meter kits which have a direct work lead jack N D If using an older control cable connect lead 75 to lead 75 of field control connect lead 76 to lead 76 of field control connect lead 77 to lead 77 of field control 515268 1 25 80 Connection of LN 8 to a SAM Motor Generator or Engine Driven Welder Connect the LN 8 control cable ground lead to the Tape up bolted connection To LN 8 input cable plug Electrode cable to control cable frame terminal marked 77 near the power source ter minal strip or to an unpaint ed frame screw The power source must of course be properly grounded Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts ELECTRIC SHOCK can kill Only qualified persons should install use or service this machine wire feed unit If using older LN 8 control cable prior to use of A B C marking Connect lead 76 to 76 on termi nal strip connect lead 77 to 75 on terminal strip and tape up lead Remove SAM portable field control amp 75 connect B amp C from LN 8 control cable Do
136. he electrode Direction of inching is controlled by the Direction of Wire Feed switch If the electrode is inching in the wrong direction reverse the position of the switch If the drive rolls do not turn check to see that the grounding lead protector is set WARNING When inching the electrode and drive mechanism are always hot to work and ground and remain hot several seconds after the gun trigger is released Operating Instructions Sec K3 1 1 Continued 3 Trigger Interlock With the Trigger Interlock switch Off the wire feed motor runs and the welding circuit is energized only when the gun trigger is pressed The operator must hold the trigger in from the start to finish of the weld To stop the arc release the trigger and lift the gun from the work With the Trigger Interlock switch On the operator holds the trigger until the arc is established then the trig ger can be released When the weld is completed the operator raises the gun from the work to break the arc This stops the wire feed and de energizes the welding cir cuit 4 Wire Reel Brake The mount for standard 50 and 60 pound 22 7 and 27 2 Kg electrode coils includes a two position brake assem bly Generally the brake should be at the inner position nearest to the wire reel shaft for wire feed speeds below 400 in min It should be at the outer position for faster wire speeds To adjust the brake position rem
137. he extension cable per Sec K2 2 10 The wire reel mount and flux tank can be removed from the undercarriage and located where convenient for a specific installation LN 8SE Meters Optional November 1990 Sec K2 2 2 LN 8F Installation 1 Wire Feed Unit Install the wire feed unit in the desired location using the mounting plate attached to the gear box See the dimen sion drawing included in this manual for hole location and size Since the wire feed unit is at welding potential when welding be certain there is no electrical contact between the gear box and the structure on which it is mounted Locate the unit so the drive rolls are in the vertical plane to minimize dirt accumulation around the rolls Also position the unit so the electrode feed cable points down at about a 45 angle to avoid a sharp bend in the gun cable where connected to the wire drive mechanism 2 Control Box a Place the control box in a convenient location close enough to the wire drive unit that the 15 4 5 m extension cable assembly will reach between them b The control box includes two keyhole slots as indicat ed in the dimension drawing included in this manual Drill the required matching holes in the mounting sur face c Install two 1 4 20 screws but do not tighten The Lincoln Electric Company Cleveland Ohio 44117 1199 d Remove the L shaped cover from the top and upper front of the control box e Mount the control box a
138. ic amp Power Mig K466 7 Hobart Series 2000 Coarse Thread Nozzle 1 8 3 2mm Recess KP24CT 62 S 1 8 3 2mm Recess KP24CT 75 S 1 4 6 4mm Recess KP24CT 62 R 1 4 6 4mm Recess KP24CT 75 R K466 8 Lincoln K466 9 SP100T and Related Units Coarse Thread KP34CT Insulator Assembly K466 10 Lincoln 10 Series See Magnum 300 amp 400 Parts Manual for part numbers Gun Tube Insulator KP2169 1 Except LN8 or LN9 using 1 16 and larger electrodes 9 LN8 LN9 using 1 16 and larger electrodes Requires Coarse Thread Insulator Assembly MAGNULM 300 amp 400 GMAW GUN 05 03 2010 LINCOLN 5 P 202 C 5 PARTS P 202 C 5 PARTS LIST OF MAGNUM CONNECTOR KITS K466 1 Connector Kit Lincoln Wire Feeders Gas Tubing Tubing Clamp 2 required Connector Assembly Includes Set Screw Insulation Tube Gun Control Cable Hose Nipple Socket Key Wrench T10642 127 T13777 4 S18645 S11604 51 T7028 234 M15608 T14557 7 T11563 4 S18845 K466 6 Connector Kit Wirematic Connector Assembly Includes Set Screw O Ring 2 required Gun Control Assembly Socket Key Wrench S18653 S11604 51 T13483 8 M16325 T11563 4 S18845 K466 2 Connector Kit For Tweco Adapted Feeders Connector Assembly Includes Set Screw O Ring 2 required Socket Key Wrench Hair Spring Cotter Pin S18653 S11604 51 T13483 8 T11563 4 S18845 S19762
139. ing insulation constant current dial plate and either a flux tank or K119 flux cone for use with a K112 or K113 submerged arc gun To install turn all power off Mount the PC board and its insulation on the LN 8N and LN 8NE panel between the switches and the circuit breaker or the LN 8F left wall of the control section Use the screws provided with the PC board Locate the connector on the end of the harness lead assembly and grasping both connectors remove the plug This jumper plug will no longer be needed as long as the constant current PC board is installed in the unit Plug the connector into the constant current PC board receptacle making certain it is seated properly Install the new dial plate over the old one Be sure the wire feeder and power source are properly set for constant volt age or constant current as appropriate see Sec K2 3 2 November 1990 M URS The Lincoln Electric Company Assembly and Installation Cleveland Ohio 44117 1199 OPTIONAL FEATURES CONT D Sec K2 5 15 K224 Solid State Remote Control Can be substituted for the K200 Portable Field Control to move the full range output control from the power source to the LN 8 when using SAF 600 SA 800 and SAN motor generator power sources It mounts on the power source Installation instructions are shipped with the kit June 1975 COMPANY tumawa omo LINCOLNA ED ZO fou Ra Th Vi i
140. instruction manual Make final adjustments with the LN 8 Volts control or the Fine Voltage Control on the optional Line Voltage Compensator Volts Control SAM Power Sources Set the power source for about the voltage required per the SAM instruction manual Make final adjustments with the LN 8 Volts control If using the variable inductance control see SAM instruction manual set the SAM Current Control as desired in the 8 o clock range Volts Control SAF 600 SA 800 and SAN Power Sources Be sure the SA 800 or SAF 600 Voltage Range switch is set to Low and the cable from the power source con tactor box is connected to the Innershield stud Exception When a slightly drooping output curve is needed with the SAF 600 usually when welding with less than 30 volts connect the input cable to the 450 Max Sub Arc stud To adjust output voltage 1 If the K200 Portable Field Control see Sec K2 5 13 is installed use the field control rheostat mounted to the side of the LN 8 2 If the K224 Solid State Field Control see Sec K2 5 15 is installed use the LN 8 Volts control 3 If neither field control is installed use the Voltage control on the power source 2 Making Test Welds 3 32 2 4 mm NS 3M Electrode with 2 3 4 70 mm Electrical Stickout a Be sure the power source and wire feeder are properly set for constant voltage
141. ip Optional T12236 5 64 KP2088 3 1 X Gun Assembly Includes Items 3 thru 20 L5757 A 1 X 3 Socket Head Cap Screw T9447 22 1 X 4 Nozzle Includes 513816 1 X 4A Nozzle Liner Tight Wound Steel Spring T12931 2 1 X 4B Liner Locking Screw T12932 2 1 X 5 Gun Tube S13042 1 x 6 Right amp Left Gun Mount L3828 1 x 7 Flux Shut Off Assembly S11686 1 X 8 Receptacle Clamp T11521 1 X 9 Spring T11514 1 X 10 Lever S11567 1 1 X 12 Pivot Pin 111546 1 x 13 Rivet T10167 1 1 X 14 Plain Washer S9262 39 1 x 15 Spring Clip S11685 1 X 16 Trigger 511569 1 X 17 Snap Ring S9776 16 1 X 18 Gun Hanger T11523 1 X 19 Roll Pin T9967 23 1 X 20 Collar S12964 1 1 X Handle amp Conductor Cable Asbly Includes Items 26 thru 42 L5757 B 26 Clamping Ring S12903 1 X 27 Tube Insulator T11584 1 X 28 Handle 511629 1 X 29 Flux Tube 11822 1 X 30 Control Cable Includes M9473 1 X Micro Switch S12182 1 1 X 30A 3 Contact Receptacle Gun End T11155 1 1 X 30B 5 Contact Receptacle Wire End S12020 6 1 X 31 Conductor Cable Includes L5728 6 1 X 31A Handle 4 Stiffener Wire Feeder End M14048 1 X 31B Connector Wire Feeder End S12801 6 1 X 31C Connector Gun End S12802 14 1 X 31D Clamping Tube Both Ends S7748 40 2 X 32 8 32 x 1 875 FHS CF000133 2 X 33 Socket Head Screw T9447 8 1 X 34 Snap Ring S9776 28 1 X 35 Socket Head Screw T9447 21 1 X 36 Switch Mounting Plate 511588 1 X 37 248 32 x 50 RHS CF000033 3 X 38 Actuator T11527 1 x 39 Insulation 111522 3 X 40 2 56 x 4375
142. k by loosening screw 10 Loosen the ingoing guide tube clamping screw 8 Install the guide tube 9 which is stenciled in through the rear brass block Tighten the locking Screw Replace the large ingoing guide 7 tube into the rear brass block Tighten the locking screw 10 Install the outgoing guide tube 11 with its plastic insert through the front brass block Tighten the lock ing screw 12 so the dog point goes into the groove in the O D of the guide tube Setting the Drive Roll Spring Pressure a For wire sizes from 030 thru 052 8 thru 1 3 mm with wire in the system the idle roll pressure indicator should be set to the proper wire size shown on the solid side of the nameplate For 030 8 mm solid wire set the pressure indicator slightly less than the 035 9 mm marking This setting is a starting point and may have to be changed depending upon type of wire surface con dition lubrication and hardness The optimum idle roll setting can be determined when there are wire stoppages If the wire bird nests between the drive roll and the guide tube the idle roll spring pressure is too high When properly set during a stoppage the drive rolls will slip and if the electrode is removed from the cable there will be a slight waviness in the electrode for about a foot beyond the slip marks on the electrode If there is no waviness the pressure is set too low For 1 16 solid or
143. ked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 819 Gun Drive Gear Case Assembly Includes L3569 1 1 Gear Box L3568 1 2 Needle Bearing 10116 2 3 3 Retaining Ring S9776 9 3 4 Vertical Shaft Assembly S11160 1 5 Cross Shaft Assembly S11161 1 6 Shaft Cap T11226 1 7 Output Shaft Assembly S11159 1 9 69 P 110 Z PORTABLE FIELD CONTROL K200 71 P 110 Z Indicates a Change This Printing ITEM DESCRIPTION PART NO 1 2 34 5 6 7 89 Complete Control Assembly Includes K200 1 1 Control Box Assembly M12536 0 1 2 Front Panel Assembly M12498 3 Nameplate S14201 1 4 Self Tapping Screw S8025 12 6 5 Knob T10491 1 6 Rheostat T10812 47 1 7 Box Connector T9639 2 1 8 Control Cable M12499 1 9 Thread Cutting Screw S9225 30 1 Lockwasher T9695 1 1 Hex Nut 10 24 1 0 This part is obsolete and no longer available 01 16 2003 P 110 AA P 110 AA K261 WIRE FEED SPEED METER ANALOG VOLTMETER KIT
144. l Changing Generally with most LN 8 installations the end of the coil can be removed from the gun cable by either laying the gun and cable out straight and pulling the electrode end out through the nozzle or by reversing the wire feed direction and pressing the gun trigger WARNING The electrode is electrically hot to work and ground when inching Be sure the free end of the electrode is kept from touching the work or any part of the ground system as it is fed back out of the wire feeder The Lincoln Electric Company Cleveland Ohio 44117 1199 With the LN 8NE or LN 8SE extension unit use the fol lowing procedures to remove the end of the coil from the gun cable 1 Cut the end of the electrode off at the gun end Do not break it off because this puts a slight kink in the wire and makes it difficult or impossible to back it through the nozzle 2 Uncouple the gun cable from the LN 8 wire drive unit 3 Lay the cable out straight 4 Grip the electrode with pliers and pull it out of the cable from the connector end Older K112 cables have a removable liner This liner may tend to slide out with the electrode If this happens remove the electrode from the liner and replace the liner in the cable 5 Load a new reel as described in Sec K3 1 8 A or K3 1 8 B November 1990 90No Operating Instructions The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K3 1 10 Flux Tank Loading 1 Flux Tank Optional
145. l cost Note In 1977 the semiautomatic guns were redesigned to conform to Nema standards To identify a new design gun an ampere rating is stencilled on the Clamp Item 12 For new design guns use column 2 K126 SQUIRTGUN amp CABLE 06 06 2005 LINCOLN 5 0 This part is obsolete and no longer available P 103 J 1 Indicates a change this printing P 103 J 1 Use only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO 1 2134567819 Gun amp Cable Assembly Includes K126 1 X X 1 Handle M10102 1 1 eX 1 Handle M10102 1 X 2 Conductor Cable Includes 15 L6250 1 1 eX 2 Conductor Cable Includes 15 L4230 4 1 X 2 Conductor Cable Includes 10 L6250 2 1 eX 2 Conductor Cable Includes 10 L4230 11 1 X 2A Handle amp Stiffener Wire Feeder End S13099 1 X X 2A Handle amp Stiffener Wire Feeder End M14050 1 1 2B Connector Wire Feeder End S12801 3 1 X X 2C Connector Gun End S12802 12 1 eX 2C Connector Gun End S12802 3 1 X 2D Clamping Tube Both Ends S16997 2 X 2D Clamping Tube Both Ends S7748 40 2 3 Snap Ring S9776 7 1 X X 4 Clamp S15921 2 1 eX 4 Clamp S11598 1 1 X 5 Spatter Shield T12027 1 X X 6 8 32 x 1 4 PHS CF000148 4 XX 7 Socket Head Cap Screw T14438 1 eX 7 Socket Head Cap
146. l from hole in wire reel cover straighten the first six inches or so of the wire and then insert this end into the ingoing guide tube Push a foot or so of wire through Now pull the ingoing guide tube back to the rear position and rotate it 90 so that it will remain in this position dur ing the cranking operation Pull the plastic hand crank handle to the out position in the arm Pull the shaft and drive roll assembly to the out position with the left hand Apply a downward pressure to the idler roll pressure arm with the right hand Maintain this pressure and start cranking the wire thru the system Keep the conductor cable as straight as possible during the loading operation This will make it much easier to crank the wire through Operating Instructions Sec K3 1 8 A Continued Crank until the wire touches the drive roll and then pull the gun trigger and this will start the drive rolls and feed the wire the rest of the way through the cable and gun assembly WARNING The electrode and drive mechanism are always hot to work and ground while inching with the gun trigger TT ID Push the plastic of the hand crank to the in position also shift the ingoing guide tube to the forward position The proper position for the hand crank arm when it is not being used is shown in the sketch below Close the wire reel door November 1990 brass blocks K3 1 8 B Wire Reel Loading Readi Reels and t
147. lain Washer S9262 3 3 27C Lock Washer T4291 A 3 27D Round Head Screw 8 32 x 1 125 3 31 Gear Box Assembly See Above 1 0 This part is obsolete and no longer available 06 12 2001 P 107 G P 107 G WIRE DRIVE MECHANISM DIA L6823 12 20 84J 10 22 97 P 107 G 1 P 107 G 1 Indicates a Change This Printing For LN 6 use parts marked X in Column 1 For LN 8N and 8S use parts marked X in Column 2 For LN 8F use parts marked X in Column 2 ITEM DESCRIPTION PART NO QTY 1 2 3 5 6 7 8 1 Drive Motor amp Gear Box Parts Code 8815 to 9000 See 110 1 Drive Motor amp Gear Box Parts Below Code 8815 8 Above 9000 See P 107 F or 2 2 Compression Spring T10247 10 3 Yoke Setting Indicator T12689 4 Button Head Socket Screw T11551 1 5 Hollow Set Screw S11
148. leads to the two terminal strips per the appropriate connection diagram if 50 hertz is used reconnect contactor coil leads per the wiring diagram 90 Below Above Code Code 8020 8020 Opposite polarity operation DC 400 DC 600 R3S and SAM SAF 600 and SA 800 with solid state remote field control M14551 M13918 M13916 M13720 M13706 M13704 M13914 Same polarity operation DC 400 DC 600 R3S and SAM SAF 600 and SA 800 with solid state remote field control M14550 M13917 M13915 M13736 M13705 M13703 M13913 Connect the dual process contactor kit control cable to the power source per the connection diagram Two 3 0 leads are provided to connect the power source output studs to the kit for opposite polarity operation Only one lead is used for same polarity operation Connect work lead and wire feeder electrode leads as shown on the diagram Put cover back on control box and unit is ready to operate CAUTION When fixture mounted wire feeders are used the wire reels must be insulated from each other and insulated from their mounting structure j COMMECT A Wit CONNECT B WIRE ELECTRODE FEEDER ELECTRODE AMG CONTROL CABLE AMD CONTROL CABLE 10 10 THis SBE MODE SWITCHES WI en sor V SUBMERGED ARC am CV INNERSMIELD FEEDER jJ A POWTR SOVICE MODE SWITCH MUST B AU 00 CY POS
149. lectrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 VE ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 f LINCOLN 8 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or
150. ludes M13349 1 X Instrument Panel Assembly Includes M13109 1 X 2 Insulation S15960 1 eX 2 Insulation 515712 1 X 3 Control P C Board L5767 1 eX 3 Control P C Board L5040 1 X 4 Trimmer P C Board S15680 1 X 5 Relay P C Board Above Code 8750 L5769 2 1 eX 5 Relay P C Board Code 7900 to 8750 L5769 Note 1 1 eX 5 Relay P C Board L5142 1 1 X 7 Transformer amp Receptacle Assembly S14165 140 1 X 8 Fuse Holder Block S10289 1 X I 8 Fuse T10728 14 1 X 9 Relay S13929 6 1 X X For replacement of a Relay P C Board that has a soldered to board Relay also order an Item 9 Relay Note 1 This P C Board can be replaced with the same basic numbered P C Board with the same or higher dash number 2 91 NOTES P 107 F 2 P 107 F 2 GEAR BOX AND DRIVE MOTOR ASSEMBLY For LN 8 Codes between 7901 and 8815 amp Above 9000 Only M14310 11 5 82N MOTOR LEAD ORIENTATION FOR NA 5R TYPE ASSEMBLIES MOTOR LEAD ORIENTATION i FOR LN TYPE ASSEMBLIES N W L5743 4 15 83R
151. m wire NOTE Connector part with 749 747 19 18 mm Dia should be made from brass if it is to be part of the welding current carrying circuit Switch requirements 1 2 Amp A C 24 volts Inductive 1 2 Amp D C 24 volts Inductive To gun switch gt Connect leads to pins A amp S12024 1 L E Part No Amphenol AN3057 10 or equivalent 12020 6 L E Part No Amphenol MS 3106A 18 11P or equivalent November 1990 The Lincoln Electric Company M 14678 Wiring Diagram Cleveland Ohio 44117 1199 LN 8F WIRING DIAGRAM Optional meter kit receptacie Power input X To front brass cabie from block on wire feed unit 568 567 power source v 4 A 6 5 7 H 9 Frame stud GND Sa ar 1 Grounding lead 54 J rH protector a J em GND TEZ Jumper connector a gt gt 32 10 gt gt 504 kk gen Control 2 gt gt 7 i Relay 4 gt gt 53t E gt P C Board S S Board 1149 54502 oed e 511 14 lt 224 1042 gt 543 842 2d 523 gt 635 12 32A u ES Variable Voltage 539 AES AE P C Board optional 555 2 r636 gt gt gt 637 gt j 164 gt 837 x lt 6 gt gt 636 Js smp BY 6 gt gt 557 gt EA gt 57 i 1 gt 04 835 3 gt gt 627 L J E 9 gt gt 631
152. metal SH FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts
153. n DC 250 Positive Negative Electrode cable to wire feed unit work Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and position the switch on power source and wire feeder if equipped to proper polarity Also refer to note N G N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N B Extend lead 21 using 14 AWG or larger insulated wire physically suitable for the installation An 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For con venience this extended 21 lead should be taped to the welding work lead If the length of work lead circuit is short and connections can be expected to be reliable then control cable lead 21 does not need to be extended and can be directly connected to terminal 21 on the terminal strip Note that this is not the preferred connection because it adds error to the wire feeder voltmeter reading N C Tape up bolted connection N D Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip The power source grounding terminal marked 77 and located near the power source input power connections must be properly connected
154. n it 2 Magnetic Separator Optional The K58 is a permanent magnet type separator designed to fit the top of the standard fill funnel of the continuous flux feed system of the top of the K219 flux hopper of a full automatic head The purpose of the separator is to remove magnetic mate rials such as mill scale and any other extraneous magnet ic materials which may have been recovered along with the flux to be processed It is important to remove these magnetic particles from the flux which is to be reused in the continuous flux feed ing system If the magnetic material is not removed it will gather around the nozzle of the gun and impede or shut off the flux flow when making relatively long welds or welding continuously The magnetic particles can also cause porosity in the weld Fit the magnetic separator into the funnel or hopper Pour the flux to be reclaimed into the top pan of the separator The separator is designed so the flux flows around three permanent magnets The magnets remove all magnetic particles When the magnets become covered with their full load they automatically stop the flux flow When the flux flow stops remove the separator from the funnel or hopper Turn it over and open the panel that covers the magnets Remove the magnetic particles with brushing or an air blast Be careful to protect yourself and others in the area from flying particles 90No or hardsurfacing flux except 535 The magnetic sep
155. nd tighten the screws 3 Extension Cable The extension cable between the wire feed unit and the control box consists of a multiconductor control cable and an electrode cable Insert the right angled polarized connector on the control cable into the mating receptacle on the wire feed unit If more convenient for the installa tion this receptacle can be rotated 180 by removing the four mounting screws rotating the receptacle and replac ing the screws Feed the other end of the control cable thru the cable clamp on the control box and connect the leads to the like number terminals on the terminal strip Tighten the cable clamp Connect the electrode cable to the front brass block on the wire feed unit Connect the other end to the left side of the shunt at the LN 8F con trol box 4 Input Cable The input cable consists of a multicolor control cable and an electrode cable Insert the polarized connector on one end of the control cable into the matching connector on the LN 8F control box Bolt the electrode cable to the right side of the shunt at the LN 8F control box Replace the cover Old LN 8F controls below code 7575 have no shunt Bolt electrode cables from the extension and input cables together and insulate with elec tricians lape Boom mounted LN 8F Wire Feed Unit 5 Electrode Routing The LN 8F wire reel mounting and the system of routing the electrode to the wire feed mechanism must be engi neered by the fixture
156. nglish Metric Gas Diffuser Industry Ref Wire Size Wire Size For 15 ft 4 5 m KP44 3545 15 035 045 0 9 1 2 mm and less KP44 116 15 052 1 16 1 3 1 6 mm Trim to Fit KP44 564 15 1 16 5 64 1 6 2 0 mm KP42 25 15 025 030 0 6 0 8 mm Standard Duty KP14 25 or KP14 25 B100 025 KP14 30 or KP14 30 B100 030 KP14 35 or KP14 35 B100 035 KP14 40 or KP14 40 B100 040 KP14 45 or KP14 45 B100 045 KP14 52 or KP14 52 B100 052 KP14 116 or KP14 116 B100 1 16 KP14 564 or KP14 564 B100 5 64 KP14A 364_or KP14A 364 B100 3 64A Heavy Duty KP14H 35 or KP14H 35 B100 035 KP14H 40 or KP14H 40 B100 040 KP14H 45 or KP14H 45 B100 045 KP14H 52 or KP14H 52 B100 052 KP14H 116 or KP14H 116 B100 1 16 KP14H 564 or KP14H 564 B100 5 64 KP14AH 364 or KP14AH 364 B100 3 64 A KP14AH 116 or KP14AH 116 B100 1 16 A For cables 25 ft KP44 3545 25 035 045 0 9 1 2 mm 7 6 m and less KP44 116 25 052 1 16 1 3 1 6 mm Trim to Fit KP44 564 25 1 16 5 64 1 6 2 0 mm Cable Liner Part Number English Metric for Aluminum Industry Ref Wire Size Wire Size For 10 ft 3 m KP1958 1 030 035 Trim to Fit KP1958 5 035 3 64 KP1958 3 1 16 Tapered KP14T 25 or KP14T 25 B100 025 KP14T 30 or KP14T 30 B100 030 KP14T 35 or KP14T 35 B100 035 KP14T 40 or KP14T 40 B100 040 KP14T 45 or KP14T 45 B100 045 KP14T 52 or KP14T 52 B100 052 KP14T 116 or KP
157. not connect lead A Lead must be taped up To work N A Extend lead 21 using 14 or larger insulated wire physi cally suitable for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrical ly separate from the welding work lead circuit and con nection For convenience this extended 21 lead should be taped to the welding work lead This extend ed 421 lead connection replaces the need to employ the remote work lead accessory on LN 8 meter kits which have a direct work lead jack 14610 4 20 79 Assembly and Installation Sec K2 3 3 G The Lincoln Electric Company Cleveland Ohio 44117 1199 Connection of LN 8 NA 3 or LT 7 to SAF 600 F or SA 800 F and M G Solid State Field Control and K240 Contactor Kit Note Electrode polarity switches on power source and field control must be set for same polarity Power source must be off when changing polarity SAF 600 or SA 800 F control box Optional t Field control con 1 i input cable To semi automatic le_ or automatic control box N B N C K240 contactor kit 115 V 60 Hz to reconnect for Hz see instructions on inside cover N D To auto Note 600 amp capacity equip A Electrode cable to semi s automatic or automatic shunt To work 515481 1 25 80 mie Sec K2 3 3 H Connection of LN 8 or NA 3 to
158. nterlock con tactor and set procedure Subsequent welding with the same gun can be done in a normal manner If the trigger is not operated once when changing feeders the first weld start may be poor if the voltage setting of the two feeders is far apart Troubleshooting Trouble Electrode feeds but is electrically cold Poor bead shape or arc response when using DC 600 power source No control of power source output Poor starting when using DC 600 below Code 8200 Poor starting or burn back on the first weld when changing wire feeders ause and Remedy Transfer switch is in wrong position Place in correct position Mode switch in wrong position on dual process contactor kit or on welder Place in correct position Power source voltage control switch not set to remote Set power source per its instruction manual Defective relay in kit Check operation of 1CR and replace if defective Defective wire feeder control rheostat Refer to operating manual Improper connection on power source terminals N P and S Refer to connection diagram to connect properly Relays not transferred properly Actuate gun trigger once before starting when changing from one wire feeder to another November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions SEC K3 OPERATING INSTRUCTIONS CONTROL ADJUSTMENTS AND LOADING THE MACHINE WARNING Do not operate with covers removed
159. o Kiez d 13 5 Kg Spools K377 and To mount a 30Ib 13 5 Kg Readi Reel package using the formed sheet metal K363 type adapters remove the locking collar and remove the outside Readi Reel adapter arm Engage the inside Readi Reel adapter arm in the brake driv ing pin and rotate the spindle until the inside adapter arm is in the vertical position Set the Readi Reel on the adapter arm The Readi Reel must be installed so that it will rotate in a clockwise direction when feeding wire is dereeled from the bottom of the coil The outside adapter arm is then to be placed on the spindle at an angle of 90 from the inside adapter and the locking collar installed Tighten the locking collar securely To mount a 30lb 13 5 Kg Readi Reel package using the molded plastic K363P type adapter rotate the spindle and adapter so the retaining spring is at the 12 o clock position Position the Readi Reel so that wire will be dereeled in the proper direction for the wire feeder to be used Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter Slide cage all the way onto the adapter until the retaining spring pops up fully The Lincoln Electric Company Cleveland Ohio 44117 1199 WARNING Check to be sure the retaining spring has securely locked the Readi Reel in place To remo
160. oard Above Code 8750 L5769 2 1 X X 11 Relay P C Board Code 7900 to 8750 L5769 Note 1 1 X X 11 Relay P C Board Below Code 7900 L5142 1 1 X X X Relay S13929 9 1 Plastic Expansion Nut S14020 1 2 X X X Self Tapping Screw S8025 14 2 13 Direction Switch T13495 1 14 Interlock Switch T10800 20 1 X X X 16 Variable Voltage P C Board Insulation 514818 0 1 17 Variable Voltage Board Assembly L5039 1 1 18 Circuit Breaker T12287 10 1 19 Decal T13086 3 1 XIX Parts Not Illustrated Below Code 7900 Only Unless Otherwise Specified Fuse Holder S10289 1 XXX Fuse T10728 14 1 X X X Identification Sticker T12607 14 1 X X X Instrument Panel Mounting Bracket S14768 1 X Output Polarized Plug All Codes S12021 3 1 X X Input Polarized Connector All Codes S12021 12 1 X X For replacement of a Relay P C Board that has a soldered to board relay also order a relay Note 1 This P C Board can be replaced with the same basic numbered P C Board with the same or higher dash number 01 31 2003 0 This part is obsolete and no longer available P 110 E P 110 E LN 8F GENERAL ASSEMBLY N 9 NE P 110 E 1 P 110 E 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 6 7 8 9 1 Control Box Above Code 7575 See P 110 F 1 1 Control Box Case Below
161. ol toggle switch in the Output Control Remote position Total current control is now at the LN 8 Semiautomatic or automatic welding in CC mode DC 600 with stick option 1 Codes between 8000 and 8045 Turn the input power off Open the control box cover behind the nameplate for easy access to the upper terminals of the terminal strip Remove the double piggy back ter minal from 32 Separate the red lead and the black lead and tape up the red lead Reconnect the black lead to 32 Check to be sure there is still 115V AC between terminals 31 and 32 when the DC 600 is turned on 2 Codes 8046 8212 Turn the input power off Open the terminal strip access door Remove and tape up the DC 600 red lead 32 on the upper screw of the termi nal strip Amps Control SAM Power Sources Set the Current Control on the power source for about the current required Make final adjustments with the LN 8 Amps control Amps Control SAF 600 and SA 800 Power Sources Be sure the power source Voltage Range switch is set to High Connect the cable from the power source contac tor box to the sub arc stud with the lowest current range that still permits welding at the desired current For example if you want 500 amps welding current use the 300 575 stud and not the 450 stud To make the final adjustments 1 If the K200 Portable Field Control see Sec K2 5 13 is
162. om Ya 4 cO pde o MOM CHAR OIM ENOTE RED CONTROL HARRY ow SICH fec wa Sec 2 5 16 K377 Small Mounting Stand for Readi Reel Coils or 10 30 Pound 4 5 13 5 Kg Spools with 2 50 mm 1 0 This assembly includes a small frame to which is attached a wire reel spindle similar to the K162 Spindle The unit is supplied with the K363P Readi Reel Adapter so the Lincoln Readi Reel Electrode Coils can be used Without the adapter the unit is capable of handling spools with a two inch 50 mm I D a 12 inch 305 mm max O D and 4 06 inch 103 mm max width A spacer for 10 pound 4 5 Kg coils is also supplied The spindle has an adjustable braking system November 1990 Sec K2 5 17 K378 Small Mounting Stand for 13 14 Pound 6 0 6 4 Kg Innershield Coils This assembly includes the same smaller frame as used in the K377 and a fully enclosed canister system for dereeling of the 14 pound 6 4 Kg coil This system has a fixed brake for the 14 pound 6 4 Kg coil November 1990 90No The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation OPTIONAL FEATURES CONT D Sec K2 5 18 File as Sec N3 5 1 in IM 294 K317 Dual Process Kit No Polarity Change The Dual Process Kit is a transfer device that connects two wire feeders to a single power source and enables each wire feeder
163. or Parts 08 09 2005 0 This part is obsolete and no longer available P 107 X MECHANIZED HAND TRAVEL UNIT K110 NOTE FOR PROPER LEAD CONNECTIONS SEE WIRING DIAGRAM METHOD OF MOUNTING EXTENSION P 107 X L3865 4 3 81E Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO 1 2 3 4 5 6 7 8 9 t Gun Drive Unit Assembly Includes K110 1 1 Mounting Clamp M9108 1 2 Thumb Screw T9078 3 1 3 Control Cable and Plug S11837 1 5 Grommet T9274 1 2 6 Truss Head Screw 8 32x5 8 2 7 Insulator Bushing 11215 2 2 8 Drive Wheel M9122 1 9 Hollow Set Screw Cup Point S11604 13 1 11 Resistor T12731 3 1 14 Reversing Switch T13111 1 15 Insulating Plate T11221 1 16 Control Box Back M9027 1 1 17 Control Box Front M9693 1 19 Dial Plate S11163 1 20 Knob T11157 1 21 Insulation T11228 1 22 Rheostat T10812 9 1 23 Gear Box assembly See P 107 Y 1 26 Motor S11162 1 27 Adapter Plate M9109 1 28 Mounting Clamp Extension M9142 1 05 10 2005 P 107 Y x CZA GEAR BOX FOR K110 OTT 107 Use only the parts mar
164. or guns using similar nozzles for differ ent wire sizes note the identifying wire size that is sten ciled or molded in an area close to the incoming end When re assembling nozzle make certain the ceramic noz zle insert if used is placed next to the spring liner The hollow lock set screw is to be tightened to give the dimen sion specified below as measured from the end of the noz zle to the hollow lock set screw K112 500 K113 K114 K115 K116 SPRING LINER E ceramic INSERT thot used on K112 or K114 j INSERT RETAINER Not used on K112 or K114 K126 K206 289 5 64 2 0 K289 3 32 8 120 2 4 amp 3 0 K309 HOLLOW LOCK SET SCREW November 1990 Sec K6 2 6 Hand Travel Unit K110 Check the lubrication in the gear box every three months If the motor worm and its worm gear appear dry wipe a thin coating of a good non fluid grease equivalent to Clark Oil Co Sea Gull Speed Reducer Lubricant on each Do not add too much or the motor will be overloaded Lubrication for this first reduction must be by spatter and drip not by running in a pool of grease Once each year flush the gear box out and relubricate To do this remove both the output shaft assembly and the motor assembly Flush the box with a good solvent Force fresh grease through the output shaft opening Do not put grease through the motor mounting side Use about 0 6 of a cubic inch 9 8 cc of grease This is a pad 1
165. ove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit Instructions for adjusting the brake tension of the spindle for 25 pound 11 Kg spools see Sec K3 1 8 B 5 Constant Voltage or Constant Current Use a constant voltage or constant current type power source as required for the application see Sec K2 3 1 Be sure the power source and wire feeder are properly connected and set for either constant voltage or constant current as appropriate see Sec K2 3 2 6 Circuit Protection The LN 8 includes a circuit breaker field circuit fuse motor thermal protector and ground lead protector See Sec K6 1 5 for a description of the function of these components November 1990 Sec K3 1 2 Welding with a Constant Voltage Power Source 1 Adjusting Current and Voltage Amps Control All Power Sources Set the welding current or wire feed speed with the LN 8 Amps control Volts Control DC 600 Power Source Set mode switch to CV Innershield or CV Subarc as re quired Place machine output control toggle switch in the Output Control Remote position Total voltage control is now at the LN 8 The Lincoln Electric Company Cleveland Ohio 44117 1199 Volts Control Idealarc R3S Power Sources Set the power source for about the voltage required per the R3S
166. p connect lead 76 to 76 on terminal strip connect lead 477 to 477 on terminal strip Upper terminal strip 75 76 amp 77 may not appear on older R3S machines leads A B amp C should be taped up There will be no adjustment of voltage by the LN 8 voltage control Assembly and Installation Sec K2 3 3 C Connection of LN 8 to a SAN Welder Power Source Work Elect Control cable 10 wire 1 To LN 8 The Lincoln Electric Company Cleveland Ohio 44117 1199 Older LN 8 control cables are tagged 75 76 and 77 instead of A B C Electrode When using optional K200 cable Portable Field Control Remove jumper 2 24 Use this lead to jumper 22 32 Connect leads 2 and 24 from the portable field control to 2 and 24 feed unit inpet cable the power source terminal strip plug If the portable field control will not Connect the LN 8 con be mounted on the LN 8 wire trol cable ground lead to feeder connect the green lead the frame terminal from the portable field control to marked 77 near the the frame of the power source by power source terminal means of the frame stud near the strip or to an unpainted terminal strip or other secure con frame screw The power nection to the power source source of course must frame be properly grounded If the portable field control is mounted on an LN 8 tape up the green lead from the portable field control To work N A Extend lead 2
167. pacer T12967 1 1 X 7 Plainwasher S9262 14 1 X 1 8 Lockwasher E106A 15 1 X X X 9 Hex Head Screw 1 2 13 x 1 00 1 X 9 Hex Head Screw 1 2 13 x 1 75 1 X X 10 Cable Clamp S16819 1 Thread Rolling Screw S9225 8 2 X X X 12 Retaining Collar 13871 1 X 13 Readi Reel Decal T13086 44 1 X X X 14 Plainwasher S9262 14 1 e X 15 Retaining Collar M14587 1 1 X Optional Not Illustrated 10 Wire Reel Spacer S18221 1 X X X 05 09 2002 0 This part is obsolete and no longer available 125 125 STAND ASSEMBLY FOR 14 POUND REEL K378 9 10 122013 14 3 10000070000 4 IIIII IIIII 24 11 5 7 KS 2 1 22 1 28 2002 P 125 0 1 P 125 0 1 Indicates a Change This Printing Use only the parts marked X in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO QTY 1 2 3 4 67819 1 Wire Reel Support Assembly L6831 3 1 x 2 Wire Reel Housing Includes S17069 2 1 X Housing M11940 1 X Wire Sheath T14800 1 X Wire Sheath Insulating Block S17068 1 X Support Washer S15094 1 x 3 Axle S13954 1 X 4 Round Head Screw 10 24 x 875 4 X Lockwasher E106A 1 4 X 5 Washer 113984 1 X 6
168. r E106A 5 8 7 Hex Nut 1 2 13 4or5 8 Pipe Nipple T9959 11 1 9 Check Valve T11130 1 X 9 Check Valve T14410 1 10 Pipe Nipple T9959 7 1 X 10 Pipe Coupling T12390 1 1 XX 11 Street Elbow T9958 2 4 X X X 12 Caution Tag T11416 1 XXX 13 Air Line Filter S11060 1 14 Water M8985 1 1 15 Strainer S16628 1 1 X X X 16 Hex Head Screw 1 2 13 x 75 5 17 Compression Elbow 57531 1 XXX 18 Bleeder Line For LN 4 or LN 5 Also Order Items 35 8 36 T12995 1 X X X 20 Flux Tank support S12737 3 21 Copper Line For LN 4 or LN 5 Order 54893 65 o 54893 61 1 X 21 Copper Line S4893 66 1 X X 22 Male Connector T11167 2 X X X 23 Pressure Regulator S11028 1 X X X 24 Reducing Bushing T9948 1 25 Pressure Gauge S11395 1 XXX 26 Clamp 512740 1 27 Hex Head Screw 1 2 13 x 2 75 1 28 Adaptor T11248 2 X X X 29 Screen Cup T11249 2 XXX 30 Safety Valve T11394 1 31 Street Tee T11393 1 X 32 Gasket T11225 1 1 XIX X 33 Outlet Tube Cap S11155 1 34 Outlet Assembly S12739 1 XXX 35 Union T12754 1 XXX 36 Flared Copper Tube T12755 1 37 Flux Hose T10642 81 1 X 37 Flux Hose 8 Ft Boom T10642 80 0 1 X 37 Flux Hose 11Ft Boom T10642 79 1 X 37 Flux Hose 14 Ft Boom T10642 77 1 ejt JX 38 Hose Clamp Tank End S10888 27 2 X X X 40 Lift Bail Assembly M11483 1 X X Flux Funnel Not Illustrated S11062 1 X X X
169. rce as required for the application Be sure the power source is properly set for constant voltage or constant current welding as appropriate per the instruc tions in the power source operating manual Assembly and Installation Sec K2 3 2 Continued 2 Set the wire feeder for a constant voltage or constant current power source as appropriate per the following instructions a There are two nameplates on the front of the wire feed unit one mounted on top of the other Be sure the Constant Current Power Source formerly Variable Voltage nameplate is on top when using a Constant current power source When connected to a constant voltage power source be sure the Constant Voltage Power Source nameplate is on top b Turn the power to the wire feeder off Open the door to the control section and switch the power source selection switch to constant current CC or constant voltage as appropriate 3a Connect the LN 8 input cable to the power source exactly as specified on the wiring diagrams in Sec K2 3 3 Include all jumpers on the terminal strips as shown on the wiring diagrams 3b To connect to Lincoln power sources not equipped with an output contactor order a K240 Contactor Kit and see S15416 connection diagram in Sec K2 3 4 A 3c To connect to power sources equipped with a contactor but not included in Sec K2 3 3 see Sec K2 3 4 B for connection instructions 4 Connect a work lead of suffici
170. riage is standard for LN 8S and LN 8SE machines It is optional for LN 8N and LN 8NE Wheels handle and hardware are shipped with the under carriage Mount the casters at the front and wheels to the rear of the platform Be sure the round rear axle is to the rear of the mounting bolts that hold the U shaped axle member to the frame Bolt the handle to the front of the platform so the LN 8 can be titled back and wheeled like a two wheeled truck Holes for installing the wire reel sup port are provided in the platform August 1973 Sec K2 5 13 K200 Portable Field Control For SAF 600 SA 800 and SAN motor generator type power sources this control moves the output adjustment The Lincoln Electric Company Cleveland Ohio 44117 1199 from the power source to the wire feeder It is a rheostat in a box to be mounted to the control left side of the LN 8 wire drive unit using the holes provided A 25 7 5 m three conductor cord connects the rheostat to 2 and 24 on the power source terminal strip The cord can be lengthened as needed using 16 or larger wire Installation instructions are included with the kit See photo under Sec K2 5 6 The K224 see Sec K2 5 15 can be substituted for the K200 November 1990 Sec K2 5 14 Constant Current Conversion Parts Formerly Variable Voltage To convert an LN 8N LN 8NE or LN 8F for welding with a constant current power source purchase a constant cur rent PC board shipped with mount
171. rt 202 4 1 X 11 Slip on Nozzle Insulator See Chart P 202 C 6 1 X 12 Gas Nozzle See Chart P 202 C 4 1 12 Gas Nozzle See Chart 202 6 1 X 15 Decal 300 Amp S18750 1 1 X X 15 Decal 400 Amp S18750 2 1 X X 16 Collar Assembly Includes S18831 1 X X 16A Collar S18830 1 X X 16B Set Screw S11604 46 1 X X 17 Hanger M15693 1 X X 18 Contact Tip See Chart P 202 C 4 1 X 18 Contact Tip See Chart 202 6 1 X 20 Gas Diffuser See Chart P 202 C 4 1 X 20 Gas Diffuser See Chart P 202 C 6 1 X Items Not Shown Cable Liners See Chart P 202 C 4 1 X Cable Liners See Chart P 202 C 6 1 X Options Magnum Connector Kits See Chart P 202 C 4 1 X X Magnum Fast Connect Gas Tube Kit for K466 1 Order K481 1 X X Trigger requires latest version of Gun Handles Comes with 300 Amp Gun Tube MAGNUM 300 8 400 GMAW GUN 05 03 2010 LINCOLN 5 P 202 C 2 P 202 C 2 Connector Assembly MAGNULM 300 amp 400 GMAW GUN 05 03 2010 LINCOLN 5 P 202 C 3 Indicates a change this printing P 202 C 3 Use only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO 1 2 3 4 56 7 8 9 Connector Assembly 300A 10 Cable L7773 1 1 x Connector Assembly 300A 15 Cable L7773 2 1 X Connector Assembly 400A 10 Cable L7773
172. rties sous tension des porte lectrodes connect s a deux machines a souder parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine a souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le cable lectrode autour de n importe quelle partie du corps PRECAUTIONS DE SURETE POUR soudage Utiliser des lunettes avec crans lateraux dans les zones pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince a une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pres 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu a qu ils se rompent
173. s coiled up to be placed closer than three feet to the wire feeder The magnetic field that is generated by welding cur rent going through the coiled cable can falsely activate the GLP November 1990 T GROUNDING LEAD PROTECTOR PRESS IO RESET 4 Grounding Lead Protector Circuit Breaker The Lincoln Electric Company Cleveland Ohio 44117 1199 Maintenance SEC K6 2 GUN CABLE GUN AND HAND TRAVEL KIT WARNING Before any gun is serviced or disassembled remove it from the wire feeder or turn off the power source Sec K6 2 1 Gun Cables All A dirty gun cable can cause rough and erratic wire feeding Therefore the cable liner must be cleaned periodically Clean Innershield gun cables after using approximately 300 pounds 136 Kg of electrode clean submerged arc gun cables after using approximately 600 pounds 272 Kg of electrode Remove the cable from the wire feeder Lay it out straight on the floor Remove the contact nozzle tip from the gun Using an air hose and only partial pressure gently blow out the cable Work the full length of the cable by bending it back and forth and then blow it out again Repeat this pro cedure until no more dirt comes out November 1990 Sec K6 2 2 Gun Disassembly Innershield Squirtguns K115 and K126 and Submerged Arc Squirtguns K113 and K112 To remove the nozzle from the gun loosen do not remove the 1 4 20 socket head screw in the gun handle with a 3 16
174. set the appro priate voltmeter sensitivity on the rear terminal strip Jumper A to B for the Innershield process and the green Same As light will remain on over a sensitivity range of 1 volt Jumper B to C for the submerged arc process and the green Same As light will remain on over a sen 90No N sitivity range of 2 volts Set the electronic voltmeter pointer knob to the welding voltage desired While weld ing if the arc voltage is within the sensitivity range the green Same As light will remain on though fluctua tions of the welding voltage may cause occasional blink ing If the arc voltage is either high or low the green light will be off and the appropriate Over or Under light will turn on The wire feeder or power source voltage control should then be adjusted until the voltage is within the range where the green Same As light remains on The center of this range indicates that the welding volt age matches the electronic voltmeter pointer knob setting within 1 2 volt m D C WOLIMETER Lincoln Specified Procedures give voltmeter readings taken between the work and the gun cable brass connec tion block inside the LN 8 To match these voltage read ings the 21 lead must be extended directly to the work per the connection diagrams in Sec K2 3 3 dated after 6 15 79A or the Direct Work Lead must be used Inching the Electrode Press the trigger on the gun to inch t
175. t location so its control cable can be con nected to the power source terminal strip Use control box as a template to locate the four 5 32 4 0 mm diameter holes that must be drilled in the case side Mount unit with the four 10 self tapping screws provided Remove cover from Kit and connect wire feeder control cables to the terminal strips in the Kit Connect the Kit con trol cable to the power source terminal strip per the appro Assembly and Installation Sec K2 5 18 Continued priate connection diagram Replace cover on Kit and unit is ready to operate OPERATION For DC 600 set the mode switch on the front of the power source to CV Innershield Set the mode switches on the kit to the position required by the process used on the wire feeder On all other power sources the mode switches have no effect To set procedures weld with A wire feeder and set proce dure with its control dials Then weld with B wire feeder and set the procedure with its control dials With the LN 9 it is not necessary to weld Each unit will now weld at its required procedure when its gun trigger is actuated Do not try to weld with both units simultaneously because the pro cedure will not be correct and the power source may be overloaded WARNING Place unused gun so electrode does not touch work wire feeder case or other metal because both electrodes become electrically hot when either gun trigger is pulled TROU
176. the amount of flux is controlled by the internal diameter of the nozzle flux cone For suffi cient flux on some applications use the nozzle flux cones with larger I D Travel Speed Set the speed of travel with the rheostat on the mechanized travel unit Speed range is 7 to 60 inches per minute 0 2 to 1 5 m min but will vary with AC input variations Operate the toggle switch on the unit to change direction of travel The K161 Power Pack has a pod which is mounted to the front of the LN 8 and LN 9 To set an exact travel speed turn the switch on the pod or the Weld Travel Only switch on LN 4 or ML 3 machines to on or to Travel Only This turns the travel motor on without energizing the welding circuit Adjust the speed dial until you have the exact speed set Return this switch to the off position and you are ready to weld NOTICE Be sure this switch is set on off when plugging in the travel motor or conductor cables Operating Instructions The Lincoln Electric Company Cleveland Ohio 44117 1199 Figure 3 Butt Weld Arrow shows direction of travel Position the gun over the seam so the electrode feeds direct ly into the seam and the gun nozzle is perpendicular to the plate Swing the gun handle horizontally to a comfortable position for welding Be sure the travel drive wheel is paral lel to the seam Operate the gun trigger to open the flux valve start
177. the spring loaded arms of the reel proper d Tighten the cover as much as possible by hand Do NOT hammer on the spinner nut arms e Cut and remove the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires NOTE Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in back lashing of the coil which may tangle the wire and cause poor unreeling f Replace the reel on the wire feeder 2 To thread Wire into LN 8N or LN 8S 50 60 22 7 27 2 Kg Reel Mounting Turn the reel until the free end of the electrode is accessi ble While tightly holding the electrode cut off the bent end Straighten the first six inches and insert the free end through the incoming guide tube Press the gun trigger and push the electrode into the drive roll Inch the elec trode through the gun If the electrode is not properly straightened it may not feed or may not go into the out going guide tube causing a birdnest WARNING The electrode and drive mechanism are always hot to work and ground while inching with the gun trigger W To thread Wire into LN 8NE and LN 8SE With Extension Slide the ingoing guide tube of the hand crank to the for ward position Remove start end of coi
178. tion replaces the need to employ the remote work lead accessory on LN 9 s which have a direct work lead jack N D Tape up bolted connection N E Connect the LN 8 or LN 9 control cable ground lead to the frame terminal marked 77 near the power source terminal strip The power source must be properly grounded N F It using an older LN 8 control cable connect lead 75 to 75 on terminal strip connect lead 76 to 76 on terminal strip connect lead 77 to 77 on terminal strip N G The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual White jumper on voltage board to 5 Blue jumper on voltage board later units olny or on start board earlier units to pin N H For DC 600 codes below 8200 Connect a jumper from N to P on LN 9 only Connect a jumper from N to S on LN 8 only There is no NPS terminal strip on codes above 516367 6 28 85N 90No Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec K2 3 3 K Connection of LN 8 or LN 9 to DC 250 400 and CV CVI Power Sources To LN 8 or LN 9 input Cable plug Power source Do not operate with covers NE removed Disconnect welding power source before servicing Do not touch electrically live parts ELECTRIC SHOCK Only qualified persons should can kill install use or service this machine CV output terminals o
179. to weld at a different procedure without changing any dials Simply actuating the circuit of the desired wire feeder turns the unit on and its controls set the complete procedure including the power source output level When used with a DC 600 the wire feeders can be set for differ ent modes CV Innershield or CV Submerged Arc Both wire feeders will operate at the same polarity The unit is a small control box that mounts on the side of the power source and is connected to the welder terminal strip Each wire feeder control cable is connected to the Kit The electrode of the wire feeder not being used will be hot although of course there will be no wire feed This usually is no problem since the unused gun or nozzle can be placed safely out of the way If however it is desired to have the unused electrode cold use a K318 Dual Process Contactor Kit connected for same polarity operation Maximum versatility is obtained when the Kit is used with a DC 600 power source The following chart shows the advantages that a DC 600 has over other welders The K317 should not be used with power sources other than those shown below Voltage Mode Mounting Power Source Range Adapter DC 400 No DC 600 SAF 600 or SA 800 with K224 Full Solid State Remote Control Parr The output range is limited by the voltage change obtainable by the remote control The voltage range between
180. tor Gun End S12802 4 1 XXX X Connector Gun End S12802 13 1 X X X X X X X X X Connector Gun End S12802 14 1 Clamping Tube Both Ends S7748 40 2 X X X X X X X X X X 2 Snap Ring S9776 7 1 X X X X X X X X X X 3 Clamp S15921 1 1 X X X X X X X X X X 4 Clamp amp Shield Assembly S12880 1 X X X X X X X X X X 5 8 32 x 25 Pan Head Screw CF000148 4 X X X X X X X X X X 6 Spatter Shield T12027 1 X X X X X X X X X X 7 Socket Head Cap Screw T9447 9 1 XXX X 7 Socket Head Cap Screw T14438 1 s X X X X X X 8 Handle M10102 1 XXX X 8 Handle M10102 1 1 XX X X X X 9 Nozzle 82 Includes M11474 120 KP1907 1 1 X X 9 Nozzle 82 Includes M11474 3 32 KP1907 2 1 X X 9 Nozzle 82 Includes M14027 82 5 64 KP1919 2 1 e je jeje je X 9 Nozzle 45 Includes M11510 120 KP1910 1 1 X X 9 Nozzle 45 Includes M11510 3 32 KP1910 2 1 e X je X 9 Nozzle 45 Includes M14027 45 5 64 KP1919 1 1 e le X Nozzle Liner Tight Wound Steel Spring 120 12931 KP2095 6 1 X X X 9A Nozzle Liner Tight Wound Steel Spring 3 32 T12931 5 KP2095 5 1 X X X s X gt 9A Nozzle Liner Tight Wound Steel Spring 5 64 T12931 32 2095 13 1
181. trical component Grounding Lead Protector The frame of the LN 8 wire feed unit and the drive motor are grounded to the frame of the power source by a lead in the control cable An overload protector prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the gun trigger is pressed When the protector is tripped the welding contactor in the power source will not close when the gun trigger is pressed As a result 1 When set for constant current welding most sub merged arc the LN 8 wire feed rolls will not turn and the arc will not strike Maintenance Sec K6 1 5 Continued 2 When set for constant voltage welding open arc the wire feed rolls turn but the arc will not strike To locate the protector reset button open the door covering the wire drive roll section and look for the round white but ton above the wire feed motor Push the button in to reset If the button does NOT move when pushed the protector is set and ready for welding Avoiding Shutdowns Caused by the Grounding Lead Protector Being Activated Do not allow the electrode to contact the case of the wire feeder or uninsulated part of its wire reel stand when the gun trigger is activated The Lincoln Electric Company Cleveland Ohio 44117 1199 Be sure that all work lead connections to the work make tight metal to metal electrical contact Do not allow excess electrode cable or work cable that i
182. trode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode e
183. ued TROUBLE _________ __ WHAT TO DO 4 LN 8 circuit breaker trips or motor ther a Motor overload a See Problem 1 and correct troubie mostat opens while welding Also see b Field fuse blown b Replace fuse Sec K6 1 5 c Electrical problems c Contact Lincoln Field Service Shop 5 No welding current Cannot establish arc To find cause pull gun trigger and Wire feed motor runs and feeds wire determine whether contactor is operating If the contactor is not operating Look under Grounding Lead Protector in Sec K6 1 5 If the contactor is operating check If voltage is present check welding cable for the voltage across the output ter an open circuit If voltage is not present check minals of the welder the troubleshooting guide of power source in question September 1980 Sec K6 4 4 Flux Feeding Submerged Arc TROUBLE I USE WHAT DO 1 Flux flow stops while welding If there is Flux tube in the gun may be blocked Remove the gun from the cable Check the tube in flux in the hose right behind the gun the gun and the cable handle test by squeezing the stoppage is in Magnetic particles may cause bridg the gun ing at the nozzle tip Bridging only Pass flux over a magnetic separator when filling occurs when welding the flux tank 2 Flux stoppage not in the gun Be cer There may be a piece of slag in the Work back along the hose squeezing it until flux tain there are no kinks or
184. uel from vaporiz ing 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding 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 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 1 f Do not put your hands near the engine fan e Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running q 1 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 LINCOLN 8 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the elec
185. unction between the two or more cables and the single 4 0 stub behind the clamp so only the single electrode lead is under the clamp 3 Pass the single electrode cable through the holes pro vided in the back corner of the control section and fasten it to the tab on the copper conductor above the rear brass block of the wire drive unit See Sec K2 2 2 for LN 8F input cable connector instruc tions COPPER CONNECTION STRAP 4 POLARIZED PLUG September 1979 Sec K2 2 10 LN 8NE and LN 8SE Input Cable Extension Cable and Reel Housing Installation The extension unit consists of a wire reel mount with a hand crank and either a 22 1 2 or 45 6 9 or 13 7 m exten sion cable assembly The cable is rated at 450 amps 50 duty cycle For higher currents install a parallel length of 1 0 cable per paragraph 10 The extension cable can be used for 068 thru 120 1 7 thru 3 0 mm flux cored electrode and 5 64 thru 3 32 2 0 thru 2 4 mm solid electrode 22 1 2 6 9 m cables can also be used for 1 16 1 6 mm solid electrodes 1 When shipped the hand crank on the wire reel mount is equipped to feed 1 16 120 1 6 3 0 mm electrode 2 The standard input cable consists of an electrode cable and a control cable with a polarized plug on the wire feeder end Position the input cable with the polarized plug at the wire reel mount 3 Connect the electrode cable of the input cable to th
186. ve Readi Reel from adapter Depress retaining spring tab with thumb while pulling Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle To mount 15 to 305 6 8 to 13 5 Kg spools remove the locking collar from the 2 inch 50 mm dia spindle Place the spool on the spindle making certain the brake driving pin enters one of the holes in the backside of the spool Be certain the wire comes off the reel in a clockwise direction Replace and tighten the locking collar brake driving pin 2 inch 50 mm dia spindle locking collar brake tension screw To feed the electrode turn the Readi Reel or spool until the free end of the electrode is accessible While tightly holding the electrode cut off the bent end Straighten the first six inches 150 mm and cut off the first inch 25 mm Insert the free end through the incoming guide tube Press the gun trigger and push the electrode into the drive roll Inch the electrode through the gun If the electrode is not properly straightened it may not feed or may not go into the outgo ing guide tube causing a birdnest Adjust the brake ten sion with the hex head screw or thumb screw on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped WARNING When inching the electrode and wire feeding system are always hot to work and ground November 1990 Sec K3 1 8 C Wire Ree
187. which hold the switch to the plate The leads that go to the switch can then be unsoldered 5 To remove the clamping ring item 26 from the han dle remove the screw item 35 and tighten the clamp screw item 33 The clamping ring may then be removed from the handle To reassemble the unit follow this procedure in reverse When finished with the reassembly make certain that the electrical connection locking screw item 36 is loosened before assembling the gun and then retightened before attempting to weld September 1979 Sec K6 2 5 Gun Nozzles All 1 Replace worn contact tips as required 2 On Innershield guns remove spatter from tip or extension guide after each ten minutes of arc time or as required 3 Replace worn spring liners in nozzles The life of the liner can be doubled by rotating liner 180 The liner can be pulled out of the back end of the nozzle by wedging the blade of a small screwdriver in the I D and pulling 4 Inner parts of nozzles can be removed and replaced by removing the internal hollow lock set screw from the contact tip end of the nozzle with a 5 32 or 3 16 4 0 or 4 8 mm Allen wrench The insert and retainer will normally fall out of the end of the nozzle but if they do not gently drive the spring liner towards the outgoing end of the nozzle The Lincoln Electric Company Cleveland Ohio 44117 1199 See appropriate parts list page for construction details and replaceable parts F

Lincoln Electric IM274-A User's Manual

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