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Lincoln Electric LN-9 GMA, Service Manual

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Lincoln Electric LN-9 GMA Service Manual Download Page 23

TABLE OF CONTENTS

- OPERATION SECTION -

Section B-1

Section B-1

LN-9 GMA Wire Feeder

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Operation

Operating Instructions .................................................................................................................B-2

Safety Precautions ......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes and Equipment.................................................................................B-3

K424 LN-9 GMA 2-Roll and K568-1 LN-9 GMA 4-Roll.........................................................B-3

K436 LN-9F GMA 2-Roll and K538-1 LN-9 GMA 4-Roll ......................................................B-3

DC Constant Voltage Power Sources ..................................................................................B-4

Controls and Settings..................................................................................................................B-5

Circuit Protection and Automatic Shutdown .........................................................................B-8

Avoiding Grounding Lead Protector (GLP) Shutdown..........................................................B-8

Drive Roll Installation ................................................................................................................B-10

Changing Drive Rolls for 2-Roll Wire Feeders ...................................................................B-10

Changing Drive Rolls for 4-Roll Wire Feeders ...................................................................B-12

Wire Loading .............................................................................................................................B-14

Loading a 22 to 30 lb. Reddi-Reel Package.......................................................................B-14

Loading a 10 to 30 lb. Spool ..............................................................................................B-15

Loading 50 to 60 lb. Coils...................................................................................................B-16

Loading and Feeding 13-14 lbs. Innershield Coils .............................................................B-17

Idle Roll Pressure Setting .........................................................................................................B-18

2-Roll Wire Feeders............................................................................................................B-18

4-Roll Wire Feeders............................................................................................................B-18

Making a Test Weld and Adjusting Response and Starting ......................................................B-19

Adjust the Power Source ....................................................................................................B-19

Adjust the LN9 GMA Controls ............................................................................................B-19

Voltage Control Response..................................................................................................B-20

Starting Characteristics.......................................................................................................B-20

Making a Weld ....................................................................................................................B-21

Procedure at End of Coil...........................................................................................................B-21

Security of Weld Procedure Settings ........................................................................................B-21

Summary of Contents for LN-9 GMA

Page 1: ...ntly think before you act and be careful SERVICE MANUAL For use with machines having Code Numbers 9100 and Above LN 9 GMA Wire Feeder Sales and Service through Subsidiaries and Distributors Worldwide...

Page 2: ...ATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommen...

Page 3: ...metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Neve...

Page 4: ...t 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 A...

Page 5: ...de d crans appropri s et non inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir che...

Page 6: ...ting Instructions B 2 Safety Precautions B 2 General Description B 3 Recommended Processes and Equipment B 3 Controls and Settings B 5 Drive Roll Installation B 10 Wire Loading B 14 Idle Roll Pressure...

Page 7: ...t d vi vi Troubleshooting Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting Guide F 4 Electrical Diagrams Section G Parts P289 Series LN 9 GMA Wire...

Page 8: ...NOTES vii vii LN 9 GMA Wire Feeder Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 9: ...de A 4 Electrical Connections LN 9 GMA and LN 9F GMA A 4 Power Input Cable Assembly A 4 Connecting the Power Input Cable Assembly to the LN 9 GMA Wire Feed Unit A 4 Connecting the Power Input Cable As...

Page 10: ...o C to 40o C 40o F to 104o F Maximum Rated STORAGE 40o C to 85o C 40o F to 185o F WIRE DIAMETERS 0 023 through 1 16 Solid Electrode 0 045 through 5 64 Cored Electrode PHYSICAL DIMENSIONS LENGTH WIDTH...

Page 11: ...point down at about a 45o angle so the wire feed gun cable will not be bent sharply as it comes from the unit MOUNTING THE CONTROL BOX The same control box is used for both the 2 Roll and 4 Roll wire...

Page 12: ...te connec tion NOTE Use of an LN 9 GMA with a Pulse Power 500 Invertec V300 or a DC650 PRO requires a K442 1 Pulse Power Filter Kit CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN 9 GMA WIRE FEED...

Page 13: ...lec trical tape CONNECTING THE POWER INPUT CABLE ASSEMBLY TO POWER SOURCES Turn input supply power to the power source OFF before connecting the LN 9 GMA or LN 9F GMA wire feeder Connect to an appropr...

Page 14: ...d DC 600 For other power sources refer to the appropriate connection diagram NOTE If you are using the Pulse Power 500 DC650 Pro or V300 power source the K442 1 Pulse Power Filter Kit must be installe...

Page 15: ...e 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 termin...

Page 16: ...nect 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 Thi...

Page 17: ...21 lead connection replaces the need to employ the remote work lead accessory on any LN 9 GMA which has a direct work lead jack N C Tape up bolted connection N D Connect the LN 9 GMA control cable gro...

Page 18: ...frame terminal marked near the power source terminal strip The power source grounding terminal marked and located near the power source input power connections must be properly connected to elec tric...

Page 19: ...st be sized for current and duty cycle of application N B Diagram shows electrode positive To change polarity turn power OFF reverse electrode and work cable at power source Set meter polarity switch...

Page 20: ...inal strip or Dual Process Kit terminal strip This extended lead must be connected directly to the work When using a Dual Process Kit you must extend the lead individual ly for each LN 9 GMA As an alt...

Page 21: ...brass conductor block on the front of the wire drive unit See Figure A 9 Make sure the connector is fully seated and tighten the plas tic thumbscrew Keep this connection clean and bright Connect the c...

Page 22: ...tall as follows 1 Connect the supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the LN 9 GMA wire drive section 2 Install the barbed fitti...

Page 23: ...ing Grounding Lead Protector GLP Shutdown B 8 Drive Roll Installation B 10 Changing Drive Rolls for 2 Roll Wire Feeders B 10 Changing Drive Rolls for 4 Roll Wire Feeders B 12 Wire Loading B 14 Loading...

Page 24: ...operating the machine SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wea...

Page 25: ...rmation Wire size range speed and features are the same as other LN 9 GMA models RECOMMENDED PROCESSES AND EQUIPMENT The LN 9 GMA is available in four models K424 LN 9 GMA 2 ROLL AND K568 1 LN 9 GMA 4...

Page 26: ...recommended for use with any LN 9 GMA model as well as the Pulse Power 500 Invertec V300 and DC650 Pro with the installation of the optional K442 1 Pulse Power Filter Kit OPERATION B 4 B 4 LN 9 GMA Wi...

Page 27: ...r when using the cold inch switch feature of the K418 and K419 options Be sure this switch is set for forward feed when you are ready to weld HOT COLD TRIGGER INTERLOCK SWITCH This switch is located o...

Page 28: ...OLS FOR LN 9 GMA OPERATION B 6 B 6 LN 9 GMA Wire Feeder Return 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 Mast...

Page 29: ...ire Feeder Return 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 FIGURE B 4 WIRE F...

Page 30: ...ore welding and without assistance Once set the control circuits of the LN 9 GMA will con tinuously monitor the volts and wire speed and correct any deviation from the set value so there will be negli...

Page 31: ...sources such as the DC 600 this protective shutdown circuit could pre vent welding under the conditions of c d and e above by holding the power source output at minimum The power source output might e...

Page 32: ...contains a spacer the spacer fits between the two halves of the drive roll Tighten the hex head screw 5 Back out the guide tube clamping screws Remove the old guide tubes if installed 6 Insert the ou...

Page 33: ...LARGE RADIUS DRIVE ROLL INCOMING GUIDE TUBE SMALL RADIUS IDLE ROLL OPERATION B 11 B 11 LN 9 GMA Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Retu...

Page 34: ...ou are installing contains a spacer the spacer fits between the two halves of the drive roll Tighten the hex head screw 7 Install the middle guide tube but do not tighten at this time When installing...

Page 35: ...ster TOC Return to Master TOC Return to Master TOC Return to Master TOC CLAMPING COLLAR SPACER IF REQUIRED DRIVE ROLL HALVES KEY OUTPUT SHAFT OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE IDLE ROLL S...

Page 36: ...Reel so that it will rotate in a direction when feeding so as to be de reeled from the bottom of the coil 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 7 Lower...

Page 37: ...eel cover much as possible by hand using the reel cover spokes for leverage DO NOT hammer on the spinner nut arms 4 Cut and remove only the tie wire holding the free end of the coil Hook the free end...

Page 38: ...hat the four arms of the cover straddle and are in line with the spring loaded arm of the reel 4 Tighten the cover as much as possible by hand DO NOT hammer on the spinner nut arms 5 Cut and remove on...

Page 39: ...lt into the reel spindle To load a 14 pound coil 1 Remove the snap on lid from the plastic canister 2 Remove the center clamping nut and the cover plate from the wire reel 3 Unpack the 14 pound coil o...

Page 40: ...t the drive roll the idle roll pressure is too great Back the pressure setting out 1 2 turn run new wire through the gun and repeat step 1 See Figure B 9 3 If the only result is drive roll slippage lo...

Page 41: ...ion Manual The LN 9 GMA requires the K442 1 Pulse Power Filter Kit See the Accessories section of this manual ADJUST THE LN 9 GMA CONTROLS 1 Set the Electrode Polarity switch to same polarity as the e...

Page 42: ...ge PC Board As set at the factory the start voltage trim level is typically about 20 higher than the LN 9 GMA SET level This gen erally gives good starting for steel cored and MIG processes using CO2...

Page 43: ...MA voltage and wire feed speed controls 1 Once the procedure is set the security panel of the LN 9 GMA can be locked to prevent access to the control knobs 2 The control range of the procedure control...

Page 44: ...S B 22 B 22 LN 9 GMA Wire Feeder Return 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...

Page 45: ...Master TOC Return to Master TOC Return to Master TOC Accessories Auxiliary Equipment Contacts C 2 Optional Equipment and Accessories C 2 Power Input Cable Assemblies K196 K595 K596 C 2 Wire Reel Stan...

Page 46: ...However the gas solenoid must be disconnected and the auxil iary equipment current draw must not exceed 1 4 ampere OPTIONAL EQUIPMENT AND ACCESSORIES POWER INPUT CABLE ASSEMBLIES K196 K595 K596 Requir...

Page 47: ...on spindle for quick changeover Included with K377 small mounting stand K438 Adapts 50 60 lb Lincoln Readi Reel coils to a K162 H spindle or similar 2 inch spindle suitable for 60 lb spools Two piece...

Page 48: ...y 2 O D casters which mount in place of the rubber feet on the wire stand Use in light duty applications where porta bility is required Can be used in combination with the K1557 1 swivel platform K155...

Page 49: ...0 Duty Process Model Electrode Rating Gas Metal Arc GMA K426 035 052 0 9 1 3 mm solid 350 amps 045 5 64 1 1 2 0 mm cored 350 amps K427 045 1 16 1 1 1 6 mm solid 500 amps 1 16 5 64 1 6 2 0 mm cored 500...

Page 50: ...essentially the same as the K317 except that the kit includes two contactors to provide different polarities on the two wire feeders When connected in this manner and one trigger is pressed the other...

Page 51: ...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...

Page 52: ...or is designed so that 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 flo...

Page 53: ...mm KP653 035S KP655 035S 0 045 and 0 052 1 2 1 4 mm KP653 052S KP655 052S 0 062 1 4 1 6 mm KP653 1 16 KP655 1 16 0 068 1 7 mm ___________ KP655 3 32 5 64 2 0 mm ___________ KP655 3 32 3 32 2 4 mm ____...

Page 54: ...S C 10 C 10 LN 9 GMA Wire Feeder Return 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...

Page 55: ...to Master TOC Maintenance Routine Maintenance D 2 Drive Rolls and Guide Tubes D 2 Wire Reel Mounting 50 and 60 lb Coils D 2 Wire Reel Mounting Readi Reels and Spools D 2 Periodic Maintenance D 2 Cont...

Page 56: ...the reel shaft periodically coat it with a thin layer of grease No maintenance of the two position adjustable brake is needed If the brake shoe wears through to metal replace the brake assembly WIRE R...

Page 57: ...art inside the gearbox The module is properly mounted to the gearbox as shipped from the factory If the device is ever removed or replaced proper mounting technique is as follows 1 Be sure all power t...

Page 58: ...24 Volts Inductive MAINTENANCE D 4 D 4 LN 9 GMA Wire Feeder Return 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...

Page 59: ...TOR TO VOLTAGE BOARD TO CONTROL BOARD METER BOARD VOLTS SPEED SWITCH T1 CIRCUIT BREAKER R1 TRIGGER CONNECTOR TRIGGER BOARD F U S E T2 C O N T R O L B O A R D VOLTAGE BOARD P O W E R B O A R D GROUND L...

Page 60: ...ject of discussion GENERAL DESCRIPTION The LN 9 GMA is a semiautomatic wire feeder that allows the user to preset the arc voltage and wire feed speed The wire feed speed is internally monitored and re...

Page 61: ...ground fault protector is reset THEORY OF OPERATION E 3 E 3 LN 9 GMA Wire Feeder Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to...

Page 62: ...voltage to comply with the command from the control board A three digit meter is provided to read both arc voltage and wire feed speed Either the preset or the actual welding parameters can be display...

Page 63: ...eed are controlled by the control board as well as the SET speed and actual speed signals for the digital meter circuitry VOLTAGE BOARD The voltage board compares the SET voltage values to the actual...

Page 64: ...ES E 6 E 6 LN 9 GMA Wire Feeder Return 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...

Page 65: ...cy Test F 38 Meter Circuit Accuracy Test F 41 Wire Speed Accuracy Test F 46 Out of Voltage Range Shut Down Test F 48 General Power Supply Tests F 51 Replacement Procedures Digital Meter and Meter PC B...

Page 66: ...OSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con du...

Page 67: ...could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers don t remove them until installation...

Page 68: ...hooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS No wire feed when gun trigg...

Page 69: ...216 383 2531 or 1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS No wire feed when gun trigger is activated The drive rolls do not turn...

Page 70: ...un trigger is not sticking 1 The relay 1CR may be faulty Replace The gas solenoid does not activate when the gun trigger is closed The wire feeds and arc voltage is pre sent 1 If a K418 GMA Timer Kit...

Page 71: ...EMS The wire feeds when the gun trig ger is activated but there is no arc voltage 1 Make sure the interlock switch is in a Wire Hot position 2 Check the welding cables for loose or faulty connections...

Page 72: ...ON PROBLEMS The SET speed is adjustable and steady The actual speed is uncon trollable The meter displays the actual speed correctly or reads EEE 1 Contact your local Lincoln Authorized Field Service...

Page 73: ...rrat ic like the SET speed 1 Check for loose or faulty con nections on leads 631 632 and 633 between the speed control potentiometer R2 and the control PC board 1 Remove power to the LN 9 GMA and disc...

Page 74: ...ON PROBLEMS The wire feeds when the interlock switch is in the ON position No welding or gun trigger activation 1 Check to see if the reed switch 2CR is stuck closed 1 Check the 2CR reed switch for st...

Page 75: ...voltage is erratic or not adjustable over the entire range of control The actual voltage is also erratic like the SET voltage 1 Check for loose or faulty con nections on leads 634 635 and 636 between...

Page 76: ...not shorted to the electrode or work cables 1 Disconnect lead 500 from the trigger PC board If the breaker still trips when the gun trigger is activated the trigger PC board may be faulty Replace 2 D...

Page 77: ...s can happen due to metal lic wire shavings build up 1 Remove input power to the LN 9 GMA Replace the 1 8 amp fuse and switch the LN 9 GMA polarity switch to the NEG position Make a resistance check f...

Page 78: ...ch es are set correctly for the process being used 2 Make certain the voltage control switch on the Lincoln CV power source is set in the Remote position 3 Make sure the 21 lead in the control cable h...

Page 79: ...feed or wire feeding is rough 1 Check or replace the gun cable It may be kinked clogged or twisted 2 Make certain the drive rolls and guide tubes are correct for the wire being used 3 Check or replace...

Page 80: ...used 2 Check the welding cables for loose or faulty connections 3 The gun cable may be faulty Check or replace 4 The gun contact tip may be worn Check or replace 6 The welding power supply may be fau...

Page 81: ...e ters and techniques are correct for the welding procedure being used 2 Check the welding cables for loose or faulty connections 3 The gun cable may be faulty Check or replace 4 The gun contact tip m...

Page 82: ...for loose or faulty connections 2 Make sure the electrode and gas if used are correct for the process being used 3 Put the Lincoln power source in the Machine Control mode Jumper the BYPASS pins on t...

Page 83: ...in error 1 Contact your local Lincoln Authorized Field Service Facility 1 Perform the Hall Effect Alignment Procedure 2 Perform the Meter Circuit Accuracy Test 3 The control PC board may be faulty Rep...

Page 84: ...e CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting a...

Page 85: ...rce in the Machine Control mode Jumper the BYPASS pins on the LN 9 GMA voltage PC board Adjust the weld voltage from the power source for the process being used If the cor rect voltage cannot be set t...

Page 86: ...d be only slightly higher than the weld voltage See Starting Charac teristics in the Operation section of this manual 2 Put the Lincoln power source in the Machine Control mode Jumper the BYPASS pins...

Page 87: ...ms 1 Adjust the start trimmer on the voltage PC board It should be slightly higher than the weld voltage See Starting Charac teristics in the Operation section of this manual 3 Put the Lincoln power s...

Page 88: ...invalidate your factory 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 t...

Page 89: ...lead 532 from the power PC board terminal See Figure F 1 Electric Shock can kill With power applied there are high voltages inside the wire feeder Do not reach into the wire feeder or touch any intern...

Page 90: ...Place the probes at the lead splices See Figure F 2 7 With 115VAC applied to the primary leads 532 and 31 if either or both of the sec ondary voltages are missing or low the T1 transformer may be faul...

Page 91: ...nvalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand t...

Page 92: ...OTECTION CIRCUIT TROUBLESHOOTING NAMEPLATE PROTECTION CIRCUIT TROUBLESHOOTING NAMEPLATE TEST PROCEDURE 1 Remove input power to the LN 9 GMA wire feeder 2 Using the phillips head screwdriver remove the...

Page 93: ...ntinued 4 Locate the T2 transformer primary lead 32A connected to the 5 amp circuit break er Remove lead 32A from the circuit break er See Figure F 4 and the Wiring Diagram 5 Lift the left side cover...

Page 94: ...Figure F 4 8 Using the volt ohmmeter check for approx imately 24VAC at the T2 transformer sec ondary leads 621 and 620 Place the probes where the leads connect on the trig ger PC board See Figure F 5...

Page 95: ...tor and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do no...

Page 96: ...RIVE MOTOR TEST continued FIGURE F 6 LEAD 539 AND 541 AT POWER PC BOARD TERMINAL STRIP LEAD 539 LEAD 541 TEST PROCEDURE 1 Remove input power to the LN 9 GMA wire feeder 2 Remove any electrode wire or...

Page 97: ...ncreased the wire feed speed should increase 8 If the above voltages are present and the motor does not operate the motor motor brushes or gear box may be faulty If the armature voltage is missing or...

Page 98: ...e Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the Hall Effec...

Page 99: ...TEST PROCEDURE 1 Remove the input power to the LN 9 GMA wire feeder 2 Remove any electrode wire or disengage the drive rolls 3 Using the phillips head screwdriver remove the screws from the left side...

Page 100: ...ith the gun trigger activated or the gun ter minals jumpered together see the Wiring Diagram check leads 555 to 510 for the presence of between 4 5 10 5VDC The motor must be running This is the feedba...

Page 101: ...just touches and stops against the rotating part inside the gearbox 4 Back the module out 1 2 turn Then using the 9 16 wrench carefully snug the module locknut without rotating the module position 5...

Page 102: ...factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test proced...

Page 103: ...ued FIGURE F 9 VOLTMETER CONNECTION POINT TEST PROCEDURE Perform the following checks with the LN 9 GMA wire feeder connected to a Lincoln CV welding power source according to the proper connection di...

Page 104: ...r and while weld ing compare the SET volts and ACTUAL volts meter readings Depending upon the arc volt age characteristics of the welding process being used the ACTUAL reading may vary somewhat around...

Page 105: ...ty For your safety and to avoid elec trical 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 una...

Page 106: ...EST PROCEDURE 1 Remove input power to the LN 9 GMA wire feeder 2 Lift the right side cover assembly and remove the two screws holding the meter cover to the right side assembly Carefully remove the me...

Page 107: ...11 NOTE The coating will have to be removed from the test points 6 Test for DC volts on the meter PC board Check for 4 75 to 5 25 VDC from TP5 to lead 510C See Figure F 11 NOTE The coating will have...

Page 108: ...curacy All Models 1 Use a test meter with at least 3 1 2 digits and 0 5 accuracy 2 Connect the probe to leads 517 and the probe to lead 510C NOTE The coating will have to be removed from the test poin...

Page 109: ...atches the set tings in the table below If the test meter does not match the readings the meter PC board may be faulty Replace the meter PC board TROUBLESHOOTING REPAIR F 45 F 45 LN 9 GMA Wire Feeder...

Page 110: ...ur factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test proc...

Page 111: ...tly 10 revolutions of the drive rolls This measured length should be 53 0 8 inches 1 35 02 meters If not there may be a problem with the wire or the wire feed path See the Troubleshooting Guide Feedin...

Page 112: ...ll invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understa...

Page 113: ...PASS pins on the LN 9 GMA voltage PC board See Figure F 12 On older voltage boards these pins may be labeled B This should disable the shut down circuit ELECTRIC SHOCK can kill With power applied ther...

Page 114: ...electrode Also check the 1 8 amp fuse on the voltage PC board 9 Check the polarity switches in the LN 9 GMA and the Lincoln power source and their associated leads Set the switches to the same polari...

Page 115: ...our factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test pro...

Page 116: ...ocate the power PC board and the control PC board in the wire feeder main assembly locate the voltage PC board in the left side cover ELECTRIC SHOCK can kill With power applied there are high voltages...

Page 117: ...LY FROM PLUG POWER 525 13 5 15 5 VDC BOARD TO 510 CONTROL 10 BOARD 9 CONTROL P C CHECK 10 VDC BOARD SUPPLY FROM CONNECTOR POWER 500 9 2 10 8 VDC PLUG BOARD TO 510 CONTROL 14 BOARD 9 VOLTAGE P C CHECK...

Page 118: ...will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not unders...

Page 119: ...SCREWS MOUNTING SCREWS METER DIGITAL METER AND METER PC BOARD REMOVAL AND REPLACEMENT continued METER PC BOARD REMOVAL PROCEDURE 1 Remove input power to the LN 9 GMA Wire Feeder 2 Locate and remove th...

Page 120: ...o the prongs on the meter when you reassem ble DIGITAL METER REMOVAL PROCEDURE 1 Using the phillips head screwdriver remove the meter shield frame and bezel assembly 2 With the 5 16 nut driver remove...

Page 121: ...rator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do...

Page 122: ...the splices from leads 529 and 628 to the reed switch leads 7 Using the slot head screwdriver and 11 32 wrench remove the screws and nuts from the lead splices Note the position of the reed switch in...

Page 123: ...actory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedur...

Page 124: ...to the LN 9 GMA 2 Using the phillips head screwdriver remove the screws holding the left side cover assembly 3 Lift the cover 4 Disconnect primary lead 532 from the power PC board terminal 5 Disconnec...

Page 125: ...OOTING REPAIR F 61 F 61 LN 9 GMA Wire Feeder 6 Disconnect leads 526 and 527 from the power PC board terminals See Figure F 18 T1 TRANSFORMER REMOVAL AND REPLACEMENT continued FIGURE F 18 LEADS 526 AND...

Page 126: ...Feeder 8 Remove the two phillips head screws from the control PC board mounting panel 9 Using the 11 32 wrench remove the nut and screw from the top of the PC board mounting panel 10 Remove the clip h...

Page 127: ...quire gently prying up the control PC board mounting panel Be sure to clear all leads REPLACEMENT 15 Position the T1 transformer and use the 5 16 wrench to attach it with the two nuts and washers 16 W...

Page 128: ...lidate your factory 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 t...

Page 129: ...nsulators for reassembly 5 Using the phillips head screwdriver remove the 9 pin amphenol connector 6 Set the resistor and the amphenol connector aside as far as the lead lengths will allow This is nec...

Page 130: ...OTOR REMOVAL AND REPLACEMENT continued 11 Remove the three screws and lock washers that hold the glastic mounting to the LN 9 GMA floor assembly It may be necessary to remove the copper reed switch en...

Page 131: ...F 24 13 Using the 7 16 wrench remove the bolts and associated washers holding the glastic mounting board and mylar insulator to the gear box assembly Remove the copper reed switch energizer 14 Using t...

Page 132: ...pection plate removed in step 14 18 Attach the glastic mounting board and mylar insulator to the gear box assembly with the bolts and washers Install the copper reed switch energizer previously remove...

Page 133: ...he test requires removing or replacing any mechanical part that could affect the wire feeder s electrical characteristics OR If you repair or replace any electrical compo nent The wire feeder must mee...

Page 134: ...S F 70 F 70 LN 9 GMA Wire Feeder Return 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...

Page 135: ...urn to Master TOC Theory of Operation Section G Wiring Diagram LN 9 GMA G 3 Wiring Diagram LN 9F GMA G 4 Voltage Board Schematic G 5 Power PC Board Schematic G 6 Trigger PC Board Schematic G 7 PM Cont...

Page 136: ...ES G 2 G 2 LN 9 GMA Wire Feeder Return 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...

Page 137: ...CABLE 67 METER PANEL PLUG 510 J6 HALL EFFECT MODULE X1 WHITE BLACK 539 541 WIRE FEED MOTOR RED BLK BLUE N D B C 32 A 2 4 31 21 GND G H D F A B C E I INPUT CONNECTOR 2 R1 531 31 J1 BLACK BLACK RED RED...

Page 138: ...0B 2 522 539 S S1 B1 B P C T2 T1 B1 B P C T2 T1 BURNBACK TIMER P C BOARD OPTIONAL GMA TIMER P C BOARD OPTIONAL JUMPER PLUG IS REMOVED AND THE HARNESS RECEPTACLE IS CONNECTED TO THE OPTIONAL GMA OR BUR...

Page 139: ...1 0 35V C15 1W 15V DZ2 D15 CR1 3 2 4 75K R24 D13 D18 5 0 D A T E DR 18 LAST NO USED D LABELS 15V 8 3 8 8 CLEVELAND OHIO U S A CHK T H E L I N C O L N E L E C T R I C C O S U B J E C T T Y P E 1A 400V...

Page 140: ...521 CR2 628 SUPPLY C SUP S D G L N 9 G M A A N D L N 9 F EARTH GROUND CONNECTION N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE L SHT 2 0 NO VOLTAGE NET D LAST NO USED LABELS...

Page 141: ...0 24 VAC 620 621 DIODES TRIGGER FILENAME M17950_1AA 623 1A 600V D4 1A 600V D1 1A 600V D2 1A 600V D3 C4 20V 20V 1 4W 022 50V THE LINCOLN ELECTRIC CO WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLE...

Page 142: ...R15 50K CW R 2 0 40V 600mA Q1 C26 1 00K R16 33 2K R19 D2 S1 16 1 562 R 4 2 J10 5 15 0K R12 1 00K R14 X3 8 9 10 510A 18 15V C15 267 R2 1 00K R18 C13 D1 J10 6 525 511 15V CLOSED FAST OPEN SLOW 631 CW 6...

Page 143: ...A 400V Ch ge Sht No SUP S D G DR SHT S SCALE 9 24 93 27 10V C3 FILE S21146_1CB J14 10 J14 7 J14 2 B4 D3 D1 D2 OUT IN GND X1 4 7 35V C2 601 5 D B 602 ACTUAL 516 SET 3 9 21146 512 515 514 511 C2 510 513...

Page 144: ...233 R234 R235 R236 R237 R238 100K OHM TRIMMER 33K OHM 10K OHM 5 6K OHM 15K OHM 47K OHM 15K OHM 100K OHM 1K OHM 1K OHM 1K OHM 33K OHM 50K OHM TRIMMER 15K OHM 10K OHM TRIMMER 33K OHM 100K OHM 1K OHM 13...

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