Lincoln Electric LN-7 GMA Service Manual Download Page 87

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TROUBLESHOOTING AND REPAIR

F-23

GROUND LEAD PROTECTOR

PUSH BUTTON SWITCH REPLACEMENT

ELECTRIC SHOCK
can kill.

• Observe all safety precautions detailed throughout this manual.

Turn off input power to the wire feeder. Only qualified technicians
should perform installations, maintenance, and troubleshooting
work on the machine.

TOOLS REQUIRED

5/16 in. wrench
Adjustable wrench
Soldering iron and solder

WARNING

LN-7 GMA WIRE FEEDER

Summary of Contents for LN-7 GMA

Page 1: ...ge ne ral are a W ELDIN G SPARKS ca n ca use fire or ex plo sion Do no t we ld ne ar fla mm ab le ma ter ial Do no t we ld on co nta ine rs wh ich ha ve he ld fla mm ab le ma ter ial ARC RAYS ca n in...

Page 2: ...h as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpieceor ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Man...

Page 3: ...ot possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding or cutting can easily go through small cracks and openings to adja...

Page 4: ...king near moving parts 7 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 7 g To prevent...

Page 5: ...l travaillant proximit au soudage l aide d crans appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de...

Page 6: ...on Setting B 13 Wire Speed and Voltage Adjustment B 13 Making a Weld B 14 Wire Reel Changing B 14 Optional K416 Analog and K417 Digital Voltmeter Kits B 14 Flux Tank Loading B 15 Accessories Section C...

Page 7: ...nections A 3 Work Cable A 21 Gun and Cable Assemblies A 21 Gun Cable Connections A 21 Water Connections for Water Cooled Guns A 22 Shielding Gas Hookup A 23 Section A TABLE OF CONTENTS INSTALLATION SE...

Page 8: ...700 in per minute 1 90 to 17 8 m min LENGTH TOTAL WEIGHT LESS ELECTRODE 24 lbs 10 9 kg 0 023 in through 1 16 in 0 6 through 1 6 mm 0 045 in through 5 64 in 1 2 through 2 0 mm solid electrode cored ele...

Page 9: ...diagrams in Figure A 3 through A 17 for the specific power source Table A 1 lists each figure number with its corresponding power source INSTALLATION A 3 LN 7 GMA WIRE FEEDER WARNING Figure Power Sour...

Page 10: ...ources without an internal output contactor and requiring a K240 Contactor Kit see Figure A 13 3 If input cables longer than the standard length must be used K292 extension cables 50 ft 15 2 m can be...

Page 11: ...nput control cable polarized Amphenol plug into the mating 6 pin receptacle on the rear of the control section 6 Referring to Figure A 2 install the input cable under the wire reel mounting stand stra...

Page 12: ...to Master TOC Return to Master TOC Return to Master TOC INSTALLATION FIGURE A 3 LN 7 GMA TO DC 400 DC 250 AND CV CVI POWER SOURCES WITH TERMINAL STRIP CONNECTION DIAGRAM LN 7 GMA WIRE FEEDER 77 CLEVE...

Page 13: ...n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN 7 GMA WIRE FEEDER INSTALLATION A 7 FIGURE A 4 LN 7 GMA TO PULSED POWER 500 CONNECTION DIAGRAM CLEVELAND OHIO U S A ELE...

Page 14: ...eturn to Master TOC Return to Master TOC Return to Master TOC INSTALLATION FIGURE A 5 LN 7 GMA TO CV CVI POWER SOURCES WITH 14 PIN AMPHENOL CONNECTOR CONNECTION DIAGRAM LN 7 GMA WIRE FEEDER ELECTRIC S...

Page 15: ...N 7 GMA WIRE FEEDER FIGURE A 6 LN 7 GMA TO CV CVI POWER SOURCES WITH TWIST MATE CONNECTOR AND 14 PIN AMPHENOL REMOTE CONTROL CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTRIC SHOCK CAN KILL TURN OFF IN...

Page 16: ...ster TOC Return to Master TOC Return to Master TOC Return to Master TOC INSTALLATION A 10 FIGURE A 7 LN 7 GMA TO CV CVI POWER SOURCE K867 K775 CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTRIC SHOCK CA...

Page 17: ...to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A 8 LN 7 GMA TO R3S 250 OR R3S 325 CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTRIC SHOCK CAN KILL TURN INPUT POWER...

Page 18: ...r TOC Return to Master TOC Return to Master TOC Return to Master TOC INSTALLATION A 12 FIGURE A 9 LN 7 GMA TO SAM MOTOR GENERATOR OR ENGINE WELDER CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTRIC SHOC...

Page 19: ...eturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A 10 LN 7 GMA TO DC 600 CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF B...

Page 20: ...to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INSTALLATION A 14 FIGURE A 11 LN 7 GMA TO R3S 400 600 OR 800 CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTRIC SHOCK CAN KIL...

Page 21: ...er TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A 12 LN 7 GMA TO MOST LINCOLN MOTOR GENERATORS CONNECTION DIAGRAM 32 CLEVELAND OHIO U S A ELECTRIC SHOCK CAN KILL TURN INPU...

Page 22: ...N 7 GMA WIRE FEEDER WARNING LN 7 GMA TO WP250 G9 PRO ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC AUXIL...

Page 23: ...A TO RANGER 9 CONNECTION DIAGRAM INSTALLATION A 17 LN 7 GMA WIRE FEEDER ELECTRIC SHOCK CAN KILL DO NOT OPERATE WITH PANELS OPEN DISCONNECT NEGATIVE BATTERY LEAD BEFORE SERVICING DO NOT TOUCH ELECTRICA...

Page 24: ...INSTALLATION A 18 FIGURE A 15 LN 7 GMA TO RANGER 10 LX CONNECTION DIAGRAM ELECTRIC SHOCK CAN KILL DO NOT OPERATE WITH PANELS OPEN DISCONNECT NEGATIVE BATTERY LEAD BEFORE SERVICING DO NOT TOUCH ELECTRI...

Page 25: ...TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A 16 LN 7 GMA TO POWER SOURCES WITH NO OUTPUT CONTACTOR CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTRIC SHOCK CAN KILL TURN I...

Page 26: ...turn to Master TOC Return to Master TOC Return to Master TOC INSTALLATION A 20 FIGURE A 17 LN 7 GMA TO POWER SOURCES WITH CONTACTOR AND NO TERMINAL STRIP CONNECTION DIAGRAM CLEVELAND OHIO U S A ELECTR...

Page 27: ...be used with several guns In most cases Lincoln guns and cables are shipped assembled ready to weld Use the gun and cable assembly for the electrode type solid Outershield or Innershield and electrode...

Page 28: ...is not designed for use with a waterline solenoid valve you may remove the solenoid and screw the male fitting after applying sealant directly into the brass manifold block 1 Using male 5 8 18 UNF le...

Page 29: ...valve and a hose from the flow valve to the gas inlet fitting of the LN 7 GMA or the K494 Gas Solenoid Valve Kit installed on the LN 7 GMA Install per Figure A 20 and the following 1 Connect the supp...

Page 30: ...turn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A 24 NOTES LN 7 GMA WIRE FEEDE...

Page 31: ...B 8 Wire Loading B 9 Wire Reel Loading Readi Reels and Spools B 9 Wire Reel Loading 50 and 60 lb Coils B 11 Wire Loading 13 14 lb Innershield Coils B 12 Acceleration Setting B 13 Wire Speed and Volta...

Page 32: ...pen arc welding It has been factory assembled with the following features Calibrated wire feed dial 75 to 700 in min 1 9 to 17 8 m min Factory installed gas solenoid valve and gas fittings Wire drive...

Page 33: ...id valve is energized immediately when the gun trigger is closed but the time delay before the wire feeder is energized is adjustable from 0 to 1 5 seconds Turn the knob to the left for shorter delays...

Page 34: ...he ground lead which will falsely activate the GLP circuit To reset the GLP circuit press the red button above the drive rolls and to the left of the circuit breaker DRIVE ROLL INSTALLATION CHANGING D...

Page 35: ...Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN 7 GMA WIRE FEEDER OPERATION B 5 FIGURE B 2 INSTALLING DR...

Page 36: ...roll onto either output shaft using the drive key clamping collar and hex head screw Certain size drive rolls consist of two roll halves and may contain a spacer If the drive roll you are installing c...

Page 37: ...eturn to Master TOC Return to Master TOC LN 7 GMA WIRE FEEDER OPERATION B 7 FIGURE B 3 INSTALLING DRIVE ROLLS ON A FOUR ROLL FEEDER CLAMPING COLLAR SPACER IF REQUIRED DRIVE ROLL HALVES KEY OUTPUT SHAF...

Page 38: ...wire birdnests jams or breaks at the drive roll the idle roll pressure is set too high Back the pressure adjustment knob Figure B 4 out 1 2 turn Run new wire through the gun and repeat step 1 3 If th...

Page 39: ...e coil 4 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 5 Lower the Read Reel to depress the retaining spring and align the other inside cage wires with the groove...

Page 40: ...DE FEEDING AND BRAKE ADJUSTMENT 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end and straighten the first six...

Page 41: ...tates clockwise DO NOT cut the tie wires at this time 4 Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires 5 When loading 0 030 0 035...

Page 42: ...LS The K378 small mounting stand for the 14 lb Innershield coil does not have an adjustable brake It has a fixed drag built into the reel spindle To load a 14 lb coil 1 Remove the snap on lid from the...

Page 43: ...ches only circuit 1 is used Set circuit 1 in the F position for fast acceleration or in the S position for slow acceleration See Figure B 7 FIGURE B 7 ACCELERATION SETTING LATER CONTROL PC BOARDS WIRE...

Page 44: ...ifficult to pull it back through the nozzle 2 Uncouple the gun conductor cable from the conductor block on the wire feeder drive unit and lay the gun cable out straight 3 Using pliers grip the wire an...

Page 45: ...k This is an automatic disposal system in case the plant air has water and dirt in it K310 FLUX SCREEN OPTIONAL The unit was designed to fit the top of either the standard fill funnel or a K58 magneti...

Page 46: ...turn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B 16 NOTES LN 7 GMA WIRE FEEDE...

Page 47: ...Mounting Stand for Readi Reel Coils or 10 to 30 lb Spools with 2 in I D C 5 K378 Small Mounting Stand for 13 to 14 Lb Innershield Coils C 5 K292 Power Input Extension Cable 600 Amps C 5 Power Input Ca...

Page 48: ...t K320 Flux tank K376 K303 50 60 lb Wire reel mounting stand S 14543 Wire reel dust shield for K376 M 11514 Wire reel dust shield door for K303 K376 K377 Mounting stand for Readi Reels and 10 30 lb sp...

Page 49: ...on The original K162 spindle has a black spacer and the part no M14587 Parts may not be exchanged from one design to the other Do not use coils or spools heavier than 30 lbs on the original K162 spin...

Page 50: ...log meter and a polarity switch It mounts in the hinged wire drive section cover Installation instructions M15080 are included with the kit K417 DIGITAL VOLTMETER KIT Includes a three digit LED displa...

Page 51: ...ystem See Attaching the Wire Reel Stand procedure at the end of this section for installation procedures K378 SMALL MOUNTING STAND FOR 13 TO 14 LB INNERSHIELD COILS This assembly includes the same sma...

Page 52: ...and cable assembly is recommended for most welding with 0 062 in through 3 32 in Innershield electrodes at up to 350 amps Install the insulated nozzle extension or thread protector and the nozzle con...

Page 53: ...re feeder K527 WATER SOLENOID KIT Install and connect per the instructions M16261 shipped with the kit This kit is factory installed on the K440 1 LN 7 GMA K376 AND K303 50 TO 60 LB WIRE REEL MOUNTING...

Page 54: ...eturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES C 8 LN 7 GMA WIRE FEEDE...

Page 55: ...es D 2 Wire Reel Mounting D 2 Periodic Maintenance D 2 Wire Drive Motor and Gearbox D 2 Gun and Cable Maintenance D 2 Section D TABLE OF CONTENTS MAINTENANCE SECTION LN 7 GMA WIRE FEEDER Return to Mas...

Page 56: ...instructions included with the drive roll kit for installation and replacement of the drive rolls on the wire feeder WIRE REEL MOUNTING To prolong the life of the reel shaft on the 50 to 60 lb coils...

Page 57: ...Relay Circuit E 4 Auxiliary Circuits E 5 Protective Circuits E 6 Overload Protection E 6 Current Limiting Circuit E 6 Ground Lead Protection E 7 SCR Operation E 7 Section E TABLE OF CONTENTS THEORY O...

Page 58: ...gure E 1 THEORY OF OPERATION LN 7 GMA WIRE FEEDER FIGURE E 1 INPUT LINE VOLTAGE AND TRIGGER TRANSFORMER TRIGGER TRANS FORMER 24 VAC 8 8 VAC 115 VAC 115 VAC CIRCUIT BREAKER OPTIONAL METER KIT OPTIONAL...

Page 59: ...s in the relay close and energize the multiple functions of the wire feeder See Figure E 2 THEORY OF OPERATION E 3 LN 7 GMA WIRE FEEDER FIGURE E 2 TRIGGER CIRCUIT TRIGGER TRANS FORMER 24 VAC 8 8 VAC 1...

Page 60: ...er the speed setting the higher the voltage that is applied to the wire drive motor The gearbox transfers the power of the rotating motor to the drive roll On a four roll wire feeder the gearbox also...

Page 61: ...METER KITS The optional meter kit indicates the welding voltage from the electrode to the work This voltage is measured from the contact block in the wire drive compartment to the work While the analo...

Page 62: ...eaker will trip to prevent any damage to the wire feeder CURRENT LIMITING CIRCUIT The current limiting circuit limits the current that is sent to the feed motor A precision resistor in line with the f...

Page 63: ...applied to the SCR it is turned on and there is current flow from anode to cathode In the on state the SCR acts like a closed switch When the SCR is turned off there is no current flow thus the devic...

Page 64: ...eturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES LN 7 GMA WIRE FEEDER E...

Page 65: ...istor R1 Replacement F 32 Control Relay Replacement F 35 Wire Drive Assembly and Components Replacement F 37 Swing Arm Assembly Replacement for Two Roll Wire Feeders F 41 Swing Arm Assembly Replacemen...

Page 66: ...may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped according to functional problems and wire feeding problems Step 2 PERFORM EXTERNAL TEST...

Page 67: ...ng bag and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a static charge If the P C Board can t be installed immediately put it back i...

Page 68: ...nplug J104 from the control PC board and install the jumper plug See wiring diagram If the problem is solved then the timer or burnback kit may be defective RECOMMENDED COURSE OF ACTION 1 Check for th...

Page 69: ...re speed setting 2 If the correct armature voltage IS present at leads 539 and 541 and the drive motor is NOT turning then the drive motor may be defective Also check the brushes in the drive motor re...

Page 70: ...COMMENDED COURSE OF ACTION 1 Jumper the trigger leads at the power source Either 2 to 4 if on a terminal strip or C to D if on a 14 pin amphenol type connector If the power source produces the correct...

Page 71: ...un trigger is pulled check for the presence of 115 VAC at leads 7 and 32A If 115 VAC is present and the gas solenoid does not activate then the solenoid may be defective Replace per Gas Solenoid and C...

Page 72: ...ACTION 1 Check the resistance of the potentiometer over the entire range of travel The potentio meter should adjust from 0 to 10K Ohms If adjustment is not smooth and linear replace per Wire Feed Spe...

Page 73: ...ent procedure 3 If the gearbox is OK and the motor current draw IS excessive then the motor or motor brushes may be defective Check or replace 4 If motor current draw is NOT excessive disconnect gas s...

Page 74: ...shielding gas is correct and flow is proper 3 Make sure the weld joint is not contaminated RECOMMENDED COURSE OF ACTION 1 Check for correct size and installation of drive rolls and guide tubes Refer...

Page 75: ...faulty Check the resistance of the potentiometer over the entire range of travel The potentio meter should adjust from 0 to 10K Ohms If adjustment is not smooth and linear replace per Wire Feed Speed...

Page 76: ...ur safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per...

Page 77: ...rminals Energized De energized 7 1 Open Closed 7 4 Closed Open 8 2 Open Closed 8 5 Closed Open 9 3 Open Closed 9 6 Closed Open 4 Measure resistance across the contacts A resistance of less than one Oh...

Page 78: ...y warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or...

Page 79: ...ary voltages are given for a primary voltage of 115 VAC The transformer secondary voltage will vary if the primary voltage varies 4 Measure the voltage across pins 4 and 5 of the transformer plug The...

Page 80: ...warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or a...

Page 81: ...nd to the terminal connectors or amphenol plug on the welding power source end Refer to the Wiring Diagrams in Section G Table F 2 and Figure F 3 for wire designations 3 If the conductor resistance me...

Page 82: ...TER REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the wire feeder Only qualified technicians should perform installations m...

Page 83: ...n screws from the top and side of the unit See Figure F 4 2 Loosen the setscrew on the potentiometer knob and remove the knob from the potentiometer 3 Remove the nut and lockwasher holding the potenti...

Page 84: ...he lockwasher and nut on the potentiometer Tighten until snug 7 Install the knob onto the potentiometer and tighten the setscrew to lock the knob in place 8 Reinstall the cover onto the control box us...

Page 85: ...TROUBLESHOOTING AND REPAIR F 21 LN 7 GMA WIRE FEEDER CIRCUIT BREAKER REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the wire...

Page 86: ...it breaker See Figure F 5 3 Remove the retaining nut that secures the circuit breaker to the panel of the wire feeder Remove the circuit breaker from the wire feeder 4 Install the new circuit breaker...

Page 87: ...R F 23 GROUND LEAD PROTECTOR PUSH BUTTON SWITCH REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the wire feeder Only qualifie...

Page 88: ...g nut from the front of the push button and remove the push button from the control box See Figure F 5 3 Unsolder the two leads from the back of the push button 4 Solder the two leads onto the new pus...

Page 89: ...UBLESHOOTING AND REPAIR LN 7 GMA WIRE FEEDER F 25 TRIGGER TRANSFORMER REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the wir...

Page 90: ...ansformer wire connector from the control PC board See Figure F 6 3 Remove the two phillips head screws that attach the transformer to the case of the control box Remove the old transformer from the w...

Page 91: ...PROTECTOR REED SWITCH REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the wire feeder Only qualified technicians should perf...

Page 92: ...Figure F 7 3 Cut the two tie wraps that attach the reed switch to the case of the wire feeder and the tie wrap that attaches the reed switch leads to the main wire harness 4 Slide the reed switch out...

Page 93: ...TOC LN 7 GMA WIRE FEEDER TROUBLESHOOTING AND REPAIR F 29 CONTROL PC BOARD REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to th...

Page 94: ...ving the four 5 16 in screws from the top and side of the unit Label all wires and connectors prior to removal All wires and connectors must be reconnected to the same terminals from which they were r...

Page 95: ...snaps onto all seven supports Do not use excessive force when inserting control relay Excessive force can damage the control PC board If the control relay does not fit remove it and try again 12 Insta...

Page 96: ...FEEDER TROUBLESHOOTING AND REPAIR F 32 MAIN POWER RESISTOR R1 REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the wire feeder...

Page 97: ...ped with a meter kit remove the meter cable strap from the resistor mounting bolt 4 Remove the second washer hex nut and third washer from the resistor mounting bolt 5 Remove the two insulating spacer...

Page 98: ...ne insulating spacer onto the resistor mounting bolt Install the power resistor and the second spacer onto the mounting bolt Secure in place with a flat washer and hex nut 9 If the wire feeder is equi...

Page 99: ...aster TOC LN 7 GMA WIRE FEEDER TROUBLESHOOTING AND REPAIR F 35 CONTROL RELAY REPLACEMENT ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to...

Page 100: ...e top and side of the unit 2 Slide the retaining clip off the side of the control relay See Figure F 11 3 Remove the control relay by pulling out wile gently rocking from side to side Do not use exces...

Page 101: ...ll safety precautions detailed throughout this manual Turn off input power to the wire feeder Only qualified technicians should perform installations maintenance and troubleshooting work on the machin...

Page 102: ...hree motor leads through the case of the control box to the wire drive compartment 4 Remove the swing arm assembly per the Swing Arm Assembly Replacement procedure 5 Remove the hex head bolt in the bo...

Page 103: ...hers in the bottom of the gearbox 17 Coat the sealing surfaces of the gearbox covers with sealant part no E2225 and install the covers on the gearbox Secure in place with two hex head screws and lockw...

Page 104: ...MBLY AND COMPONENTS REPLACEMENT continued TROUBLESHOOTING AND REPAIR F 40 LN 7 GMA WIRE FEEDER FIGURE F 13 WIRE DRIVE ASSEMBLY REMOVAL FOUR ROLL FEEDER MOTOR ROLL PIN PINION GEAR MOTOR INSULATOR GEARB...

Page 105: ...R TROUBLESHOOTING AND REPAIR F 41 SWING ARM ASSEMBLY REPLACEMENT FOR TWO ROLL WIRE FEEDERS ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power t...

Page 106: ...r from the swing arm 3 Pry the speed clip off of the groove pin and lift the idle roll assembly from groove pin 4 Remove the two screws that hold the idle roller in the idle roll assembly Remove the i...

Page 107: ...idle roll assembly into the groove pin Secure in place with a speed clip 7 Slide the pivot pin into the swing arm assembly Place the flat washer and swing arm assembly on the gearbox assembly Fasten...

Page 108: ...F 44 LN 7 GMA WIRE FEEDER SWING ARM ASSEMBLY REPLACEMENT FOR FOUR ROLL WIRE FEEDERS ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the...

Page 109: ...pull the two swing arms out of the wire drive compartment Ensure that the two spacers are not lost 4 Remove the two socket head cap screws and flat washers from the swing arm assembly Remove the idle...

Page 110: ...o swing arms and spacers in the center post of the wire drive assembly Ensure the holes in the pieces line up to accept the hinge pin Do not use excessive force when installing the hinge pin If hinge...

Page 111: ...OCK can kill Observe all safety precautions detailed throughout this manual Turn off input power to the wire feeder Only qualified technicians should perform installations maintenance and troubleshoot...

Page 112: ...o Master TOC Return to Master TOC LN 7 GMA WIRE FEEDER TROUBLESHOOTING AND REPAIR F 48 GAS SOLENOID AND CONNECTIONS REPLACEMENT continued FIGURE F 16 GAS SOLENOID DISASSEMBLY GAS OUTLET FITTING RETAIN...

Page 113: ...solenoid from the solenoid mounting plate by removing the two phillips head screws from the bottom of the mounting plate 8 Remove the tubing from the gas and solenoid outlet fittings A knife may be r...

Page 114: ...part which could affect the machine s electrical characteristics must be replaced or if any electrical components are repaired or replaced the machine must be retested and meet the following standards...

Page 115: ...ms Codes 9168 and 9386 G 3 Codes 9643 and 9796 4R G 4 Codes 9928 and 9931 4R G 5 Schematic Diagram Control PC Board G 6 Section G TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION LN 7 GMA WIRE FEEDER Ret...

Page 116: ...on is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator...

Page 117: ...104 PC BD PLUG ASBLY OCI101 OPTOCOUPLER PHOTO Q 70V CNY17 3 PT101 TRANSFORMER PULSE 3 WINDING 1 1 1 Q101 TRANSISTOR N T225 0 5A 250V 2N5655R126 Q102 TRANSISTOR N T226 0 5A 300V MPS A42 Q103 TRANSISTOR...

Page 118: ...R I G G E R T R A N S F O R M E R N A H I R 4 0 L O W R 3 7 F S N D L N 7 G M A C O N T R O L P C B O A R D N A Q U I C K C O N N E C T T E R M I N A L S 7 T O G A S S O L E N O I D V A L V E 1 1 5 V...

Page 119: ...F O R M E R N A H I R 4 0 L O W R 3 7 F S N D N A Q U I C K C O N N E C T T E R M I N A L S 7 3 2 A N B M E T E R K I T R E C E P T A C L E N C O P T I O N A L G M A T I M E R O R N E A C T I V A T E...

Page 120: ...E R O R W 5 3 9 5 4 1 B N B J 6 G U N C O N T R O L C A B L E C O N N E C T O R C A V I T Y N U M B E R I N G S E Q U E N C E C O M P O N E N T S I D E O F B O A R D L E A D C O L O R C O D I N G B B...

Page 121: ...CEMF WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY N B CR2 GLP REED SWITCH ACTUATED BY GROUND CURRENT 2N5655 Q101 150K R114 10K R115 D113 2W 2 2K R113 B541 1 2 OPTOCOUP...

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