LENCO L-6000 LENCOSPOT MARK III User manual

LENGII
MARK III SPOT WELDER
L-6000
»WARNIN GS AND SAFEGUARDS FOR WELDING AND CUTTING OPERATIONS
Important - Protect yourself and others !_ Remember that -safety depends on you. The operator, supervisor, and ‘
helper must read and understand all warning and safety information provided in these instructions.'Serious injug
or death could result if welding equipment is not properly installed, used and maintained. Training and proper
supervision are most important for a safe work place. Installation, operation, repair work, and maintenance must be
preformed by qualified personnel. Retain these instructions for future use. A
f ELECTRICAL SHOCK CAN CAUSE INJURY OR DEATH V
-; '; Install and maintain equipment in accordance with the National Electrical Code NFPA 70 and
a local codes. Do not service or repair equipment with power on. Do not operate equipment with
I ; protective insulators or covers removed. Service or repair to equipment must be done by qualified
‘ " " e- ‘ and/or trained personnel only.
Maintain welding head, work clamps, welding cable, and welding machines and related equipment in good safe
operating condition. Replace all worn or damaged insulation. Occasionally, check all connections to determine if
they are mechanically strong and electrically adequate for the current required. Never immerse electrodes in water
for cooling. - . I g V - _
References; See Safety .and Operating References A, E H, I. . "
“ SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH .
__ » Keep smoke,fumes, and gases from your breathing zone and the general area. Smoke, fumes, and
I . ; gases from the welding process are of various types and strengths, depending on the kind of metal
1 - . . being welded on. To ensure your safety, do not breathe these fumes or gases. Ventilation must be
adequate to remove smoke, fumes, and gases during the welding procedure to protect operators and others in the _
immediate area. Fumes produced by welding or cutting, especially in confined areas, can cause discomfort and
physical harm if inhaled over an extended period of time. Always provide adequate ventilation inthe welding and
cutting area to insure breathing air is safe. Use air-supplied. respirators if ventilation is not adequate to remove all
fumes and gases. Never ventilate with oxygen, because oxygen supports and vigorously accelerates fire. V
References: See Safety and Operating References A, B, C, H, & I. A _ . .
_ HOT PARTS _
. Hot parts can cause serious burns. The area at and near the work being welded should be handled
figs: with proper gloves. Proper clothing should be worn to prevent spatter from causing bums. Never
pick up welded materral until 1t has been properly cooled.,References. See Safety and Operating
References A, B, H, &_I. -
. cnusnmc _ , 1 -
I A The electrode tips and arms can pinch hands or fingers when they are between them and the switch is
57. " - activated. Hold the head by both handles when Positioning the head for welding. Disconnect air line
"/A ' from the welder before repairing or adjusting components on the welding head.

SPOT WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS ’
,. . . . Remove any and all combustible materials from the work area. If this is not possible, cover them to
7 prevent the welding sparks from starting a fire. Causes of fire and explosion are any combustibles
.1 Ll 1 reached by flying sparks or heated materials. Do not wear any gloves or clothing that has oil or fuel
-type material on it. Always have a properly working OSHA recognized Fire Extinguisher near and be sure everyone
has proper training in its use.
All hollow spaces, cavities, and containers should be vented prior to welding for they may explode. Make sure
proper steps have been taken to ensure that venting procedures will not form flammable or toxic vapors from
substances inside containers. y
References: See Safety and Operating References A, D, E, F, G, and H
FALLING EQUIPMENT g .
A Lift only the unit or object to be moved without any running gear, assessories, or gas cylinders that
_ may be attached tohit. Use equipment of a proper size to lift and move the unit. Falling equipment can
cause personal injury_ and equipment damage. p
1 References: See Safetyand Operating References A, B, H, & I ’
_ Safety and Operating References
A) ANSI Z49. l, “Safety in Welding and Cutting”
B) ANSI Z87.l, “Practice for Occupationaland Educational Eye and Face Protection”
C) ANSI Z88_.2, “Standard Practice for Respiratory Protection” I . _ '
AN SI:_ American National Standard Institute, 1430 Broadway, New York, NY 10018 I
D) ANSI F4.1, “Recommended Safe Practices for Welding and Cutting Containers” '
AWS: The American Welding Society, P.O. Box 351040, 550 NW Lejeune RD., Miami, _FL 33135
E) NFPA 5_lB, “Fire Prevention in Cutting and Welding Process” .
F) NFPA—70, “National Electrical Code”
NFPA: National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
G) CGA P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders”
CGA: Compressed Gas Association, 1235 Jefferson Davis Hwy., Arlington, VA 222,02
H) Code of Federal Regulations (OSHA) 29 CFR 1910
US: U.S. Government Printing Office, Washington, DC 20402
I) CSA Standard W1 17.2, “Safety in Welding, Cutting, and Allied Processes”
' CSA: Canadian Standards Association, "17 8 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3
2

_ WARRANTY ’
LIMITED WARRANTY: Subject to the terms and conditions hereof, NLC, Irrc., Jackson, Missouri warrants its
products to be free from defects in workmanship and material at the time of delivery by NLC, Inc.
NLC, Inc. will honor warranty claims on products as a result of failure fiom a defect for a time period of one year
from the date of sale to the original user. Upon return of the merchandise at the user’s expense, NLC, Inc. reserves
the right to either repair or replace as necessary. This is the only warranty either expressed or implied covering our
products. '
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UNPACKING AND ASSEMBLY ‘ ,
Examine the packaging material for shipping damage, which may indicate damage to the product inside. If damage
is found, contact the shipper to resolve any issues resulting from shipping. If no damage is found, check the power
supply you intend to use to see if the plug andreceptacle will mate properly. This machine requires single-phase,
208/230 volts, 60/50Hz, and 60-amp service with delayed action breaker. Have power supply approved by a
licensed electrician. Also uses compressed air. ,-_ p
Before you hook the machine to the power and air supplies do the following. .
0 Bolt the cable support bracket to the back of the welder, and then secure the L-6000 with supplied hardware
on the cart as shown. ‘
0 Fill the cooling unit with special coolant supplied (LAS-415) and install on the lower rails of the cart with V
‘ the inlet and outlet fittings to the front of the L-6000. (Note: Save 1 quart [lliter] to prime the unitl) e I "
Hookup the inlet and outlet water lines to the cooling unit. ‘ -
Plug the cooling unit power cord into the 208/230 volt outlet on the back of the L-6000. . -
Removethe red plug on the front of the cooling unit and prime with coolant. _
Align the holes in the ends of the LEN-COOL gtm cable assembly and A-200-10 single side cable "
assembly, on opposite sides of the secondary leads on thefront of the L-6000._ (The secondary lead is in
the center.) Bolt them tightly together with the flat sides making contact. Make sure to attach the LEN-
COOL gun and the single side cable assembly on opposite sides of the secondaryleads.
0 Plug the control cord of either assembly into the mating receptacle on the front of the L‘-6000.
CAUTION: When using the LEN-COOL gun assembly, take care to ensure the electrodes and the other cable
assembly are n_ot'contacting one another or contacting any conductive material (use enclosed tip covers).
0 Plug the air fitting on the welding head into the snap fitting on the front of the L-6000.
0 I Hang the welding head on the accessory.rack and place the cable assembly out of the work area.
3

To hook the machine to the power and air supplies do the following. ‘
0 Attach the shop air supply hose to the male fitting of the air regulator on the back of the L-6000.
0 Tum the air pressure on and set the regulator to 80 psi. 1 »
~ Turn off the breaker to the shop power receptacle, attach the 50-foot power cord to the shop electrical
supply, and then turn the breaker back on.
0 Tum -on the power switch on the front of the welder and inspect the entire system for air and water leaks.
(The cooling unit starts and stops with the power switch.) ,
0 Set the timer control on the front of the machine to,3. I ' E ‘
0 Set switch for either single side or squeeze type weld procedure.
0 Set switch for Automatic Operation." . .
TEST WELDS I j . _ . "
Cut four to six pieces of metal similar to that which you-plan to weId, and clean the 2 outside areas to bare metal.
Clamp two pieces together and support them so the welding head can clamp across them to make a weld. Remove
any combustibles from the area. Also protect any nearby items which could be damaged by flying sparks. Put on
your safety glasses and any other required safety gear as needed. Make a test weld. Adjust timer control and air
pressure until desired Weld is achieved. M
SINGLE SIDE WELDINGCABLE/GROUND CLAMP p
In order to improve perfonnance and operating efficiency of the single side welding fLlI1ClIlOI1, we have now
incorporated a single electrode and ground clamp in place of the “dual spot” system. Because of the amount of
power generated by the L-6000, this will allow the user greater control, allowing for a better_weld. Instructions for
use are as follows: . I ' '
IMPORTANT: Wear proper welding gloves as the electrode, ground clamp, and area being welded can
' become very hot.
1. Unplug the switch cord on the front panel of the machine and plug in the switch cord for the single side
2. Set the timer on 2 (you can adjust up or down depending on metal thickness or local line voltage
- conditions). A_ » . _
3. _ Connect the ground clamp firmly on the same panel you are welding on. ' . V '
NOTE": Periodically check to make sure the ‘/2” bolt that connects the ground clamp to the cable lug
. "remains TIGHT. If allowed to work loose, a faulty comrection will occur, resulting in overheating and
' arcing. A ,
4. Press the electrode fnmly to the panel with enough pressure to close any gaps. A
5. Press the switch on the handle and hold it down until the welding cycle stops automatically.
SINGLESIDE ELECTRODE CARE AND SERVICE
' Q DRESSING THE TIP: The fastest way to dress the tip is to use the PTS-100 Tip Sharpener. Place the tip
sharpener over the electrode as you would a pencil sharpener. Apply pressure and twist the sharpener
several revolutions to the right. The hardened tool steel bit will quickly sharpen t-he copper tip to its
original 1/8” diameter. Use a file to dress the face of the welding tip. KEEP THE TIP DRESED TO 1/8”
_ DIAMETER FOR CONSISTENT WELDING RESULTS.
0 REMOVING THE TIP: Tap the side of the copper electrode gently several times with a bumping hammer
‘ to loosen the taper fit. The tip is then normally loose enough to remove by hand. UNDER NO
CIRCUMSTANCES SHOULD YOU ATTEMPT TO REMOVE THE TIP BY TURNNG IT IN THE
ELECTRODE. The tip is held in with a No. 1 Morris Taper (N o. 4RW) and any attempt to turn it will gall
the inside of the electrode which will cause poor contact between the tip and electrode or ruin the elecrmde
. A 4

INSERTING TIP: Wipe the No. 1 Morris Taper (No. 4RW) clean and use the STSW Brush to clean the .
inside of the electrode. This will clean out any metal filings and corrosion that may have built up inside the
electrode. Press the tip in with HAND PRESSURE ONLY. DO NOT HAMMER THE TIP INTO THE
ELECTRODE. Never insert a “cold” tip into a hot electrode. You should be able to hold the copper
electrode body with bare hands before inserting a cold tip.
If by accident you should bum a hole in the panel, it is likely that some steel will be fused to the copper tip.
Remove the fused steel by nipping the tip ends with pliers or diagonal cutters. Redress tip with LENCO
Tip Sharpener PTS-100 before continuing.
The tips will normally last about l0 months to a year. Reorder new tips from your LENCO distributor.
CABLE CONNECTION: Keep bolts tightened at the welder cable comrection. Good contact means good
welds.
BEST POSITION OF ELECTRODES FOR WELDING WITH THE SDIGLE SIDE ELECTRODE
J INT
LAP JOINTS FLANGE O
/’ ON LAP JOINTS PLACE . I \
l ELECTROD$ CLOSE T0 i ' ON FLANGE JOINTS PLACE
I. TOP EDGE FOR A TIGHT I. ELEcTRooEs on THE came , _
SEAM THAT REDUCE5 . FLANGES AND SPOT WELD
FINISHING TIME. CLOSE TO VICE GRIP JAWS. I
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HELPFUL WELDINGHINTS: Use vise grips on all flange joint and drip rail applications to bring the
parts closely together. Weld near the vise grip jaws where the fit-up is tight. ‘
A few sheet metal screws can be used on lap joints to position the panel for spot welding. Make sure
the paint has been removed from the joints. , "
On long splice jobs, start in the middle of the panel and spot weld in one direction, for example, '
the middle of the panel to the doorpost. “Start again in the middle and complete the panel welds to the 5
taillight area. This is an additional aid in eliminating distortion. l .
Removal of burrs on the newly cut panel ensures getting good metal-to-metal contact when body pressure A
is applied to the electrodes. Burrs and dents cause an air space between mating parts and prevent metal
contact. - ' . e .
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CABLE ASSEMBLY-RIGHT SIDE
ITEM# PART# DESCRIPTION
l. 26125. Complete Power Cable
2.
21122 l0’ x 4’ Cable W/Lug and Electrode Holder
UJ
21050 Welding Tip —— Regular (pkg. of 2)
-P- 29449 Molded Handle
U1 23170 Push Button Switch w/Retaining Nut
F“ 29688 Control Cord w/Plug and Ties
>1 29685 Plug Only
CABLE ASSEMBLY- GROUND
ITEM# PART# DESCRIPTION
- 8. 26126 Complete Ground Cable Assembly
9. 26127 5’, 4/0 Cable w/Lugs and Hardware‘
l0. I 02077‘ C-Style Ground Clamp w/Bolt

0 PATCH PANELS: If patch panels are cut from sheet metal to cover rust areas, make the patch big enough
to extend beyond the rust area into good body metal.
In resistance welding, the out-putcables are purposely bound together to deliver more power to the
weld. Ifthe bands should become cut, tape the cables so they are always bound together. You will
always make good welds, panel after panel, if four conditions are met:
1. Clean metal .
. 2. Good fit-up
3. Proper time setting A
4. Correct tip diameter
0 BURN THROUGH: Burn through is caused by one of the following:
1. Paint was not removed from the mating panels.
2. There were air gaps between the mating metal parts.
. The timer setting was too high for the thickness of the metal being welded. ’
The welding tips were removed from the work, before the welding cycle wasicompleted.
. The tip diameters were not equal. '
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The L-6000 must be plugged into a 208/230 volt, single phase, 60/50I—Iz, fused for 60 Amps. "
In case the L-6000 does not operate", check the main fuse box of the building wiring to
see if the main circuit fuses are not blown. ‘
WELDING CYCLE FOR THE LEN-COOL GUN - .
0 ‘When the switch on the upper handle is pressed, the tips will compress the panels together. Ifthe button is
. released the tips will open. V _
0 1.5 seconds after the -tips are closed the microprocessor takes over and welds for the time determined by the
timer setting. ' P , " ' I
0 Maintain pressure on the weld for one-half second after the weld is complete, and then release the switch to
unclamp the panel.
0 _ In case the above fails to produce a satisfactory weld, check weld area for contact between panels, adjust
- timer, or air pressure and repeat. _ _ g ..
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PARTS DIAGRAM AND ITEM CODE NUMBERS FOR THE
SQUEEZE GUN ASSEMBLY '
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Part #
. Description V
Part #
Description
26144 Welding tip w/RW taper (pkg 2) 26550 Hardware kit (2ea. 1 1/a”bolts, flat & lock washers)
IQ 26500 Complete clamp arm assembly 26551 Hardware kit (2ea. 1”bolts, flat & lock washers) _
U-)
26505
Clamp arm water tube assembly
27447
Push button switch
-{>- 26495
Hose-water w/2-90° 1/16” fittings 26193 Control cord w/plug - 7’
U1 265-l5 Water nozzle w/”O”-ring (26510) 26490 Casting hinge pin w/retaining clips (2)
O\ 26520 Water hose fitting w/clamp 26163
Handle (central)
\l 26530 Insulator bushings (2) 26470 Air cylinder pin w/retaining clips (upper &lower)
O0 26440 Cam adjuster w/ “O” ring 26405 Air hose W/male air fitting & female threads
R0 26540 Casting hinge pin retaining clips (2) 26400 Hose only — water & air - 8’
I-—l O 26460
Air cylinder-complete
26465
Air cylinder cap
3-1
;_i 26485
Casting w/set screw-lower
26466
Air cylinder cup ring
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26560 Roll pin (2) 26467 Air cylinder piston
I-1 U.) 26570 26468
Air cylinder spring
>—l -5 26480
Cap screws (upper/lower castings [2])
Casting (handle side) w/cap screw - upper 26469
Air cylinder housing
I—l
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26181
Cable w/cover, lugs, & hardware
26420
Water coupler set (male & female) w/clamps
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26162.
Handle w/ grip (rear) 29685 Male plug — control cord
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PARTS DIAGRAM AND ITEM CODE NUMBERS FOR THE L-6000 MARK HI
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Part # Description e Q 0
5 32: Part # A - . Description
26100
Welding Transformer (208/230V)
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26110 Caster w/Brake (4”)
26304 Contactor - ' v-A
O\ 26430 Coolant Circulator .
U) 29150 Control Transformer - 230V i— \I
263 80 Timer Control Assembly
-#- 23340 Air Regulator. )—l O9
23315 Air Valve .
U1 23350 Receptacle (Circulator) 0- \O
29340
Power ‘Cable-50’,l0/3 wire
ON 29745 Switch “On-Off’
26410 Panel Air Coupling (female)
\l 23330 Switch-Auto/Close
29680
Receptacle _— accepts 2 prong p ug
O0 23330 Switch-Len-Cool/Single Side
26425
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Water Coupler Set (90° male & female)
\O
29690 Timer Indicator Knob 23415 Coolant —_ one gallon
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29230
Strain Relief
26260 Complete Squeeze Type Welding Head
& Cable Assembly (Len-Cool Gun)
26349 Cabinet 1
26450 Cable Support Bracket w/Handles
26200
26109
L-6000 Cart-Complete
Caster w/o Brake (4”)
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NOTES
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NOTES
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L E V L-5000 WIRING DIAGRAM L E0
‘VI ® cnouunr ‘vi ®
Q-yi GREEN “Pl
230V RECEPTACLE
TO PUMP
LAS—35O
dwv 09
asvner EITDN s
ov anon 022
.Ll'1dNI
(INITOHEJ
IQ
on/orr
I swrrcn
LIGHT
- 5
. ..'
"' BLACK 5 #1-P 74
E11
' I
CONTROL
| CONTACTOR l TRANSFORMER
B—304 A_101
- I I
| V-Ia
VIE
'.' HO
>10
)I3V'IH
YELLOW -
!\
Cal
PRIMARY
WELD
YELLOW
z#
cIV-L A908
TRANSFORMER
B— 1 00
SEC ONDARY
I I
OUTPUT
-- T0 GUNS
BLACK
TRIGGER
RECEPTACLE
A— 3 1 6
c RED
AIR ‘VALVE _
» _ LAS—315
swrrcn SW"
e PINCH can
AUTO/CLOSE . DUAL LEAD
‘ ‘ ms-sac I-As'3,3°
.1
RED
\
PC BOARD
B-380 . .
TIMER
_
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DANGER: DO NOT CONNECT #2 and’ #3 transformer leads to contactor at same time.
For. 208V service — disconnect wire #3 from contactor and replace with wire #2, insulate wire #3.
’ For 230V service — disconnect wire #2 from contactor and replace with wire #3, insulate wire #2.
e Lenco Automotive Equipment --
For Technical Assistance Call; [phone] '
NLC, INC., 319 W. Main Street, Jackson, MO 63755 Phone [phone], Fax [phone]
I
-.
Form No. L6-0604