Lincoln Electric POWER FEED 84 Service Manual
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Lincoln Electric POWER FEED 84 Service Manual

Lincoln Electric POWER FEED 84 Service Manual

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POWER FEED 84, POWER FEED 84 DUAL,
POWER FEED 84 U.I. CONTROL BOX
For use with machines having Code Numbers:
Power Feed 84: 11986 thru 11991, 11993, 11994, 11996, 11997, 11998,
12274 thru 12284
Power Feed 84 Dual: 12108 thru 12113, 12115, 12116, 12285 thru 12292
Power Feed 84 U.I. Control Box: 12177, 12178, 12179
SERVICE MANUAL
POWER FEED 84 SINGLE
SVM255
| Issue D ate 14-Jun
© Lincoln Global, Inc. All Rights Reserved.
POWER FEED 84 U.I. CONTROL BOX
POWER FEED 84 DUAL
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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  • Page 1 For use with machines having Code Numbers: Power Feed 84: 11986 thru 11991, 11993, 11994, 11996, 11997, 11998, 12274 thru 12284 Power Feed 84 Dual: 12108 thru 12113, 12115, 12116, 12285 thru 12292 Power Feed 84 U.I. Control Box: 12177, 12178, 12179 SERVICE MANUAL POWER FEED 84 U.I.
  • Page 2 POWER FEED 84, POWER FEED 84 DUAL SAFETY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety...
  • Page 3 American Welding Society, P.O. Box 351040, Miami, Florida 33135 MAGNETIC FIELDS MAY or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 POWER FEED 84, POWER FEED 84 DUAL SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover electrically “hot” when the welder is on. Do plates to protect your eyes from sparks and the rays of the arc not touch these “hot”...
  • Page 5 POWER FEED 84, POWER FEED 84 DUAL SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area.
  • Page 6 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding equipment, in metallic conduit or equivalent. Shielding should be Equipment. It is for use with other Lincoln Electric equipment. It is electrically continuous throughout its length. The shielding should be designed for industrial and professional use.
  • Page 7 POWER FEED 84, POWER FEED 84 DUAL SAFETY Ventilation As a rule of thumb, for many mild steel electrode, if the air is visibly clear and you are comfortable, then the ventilation is generally There are many methods which can be selected by the user to adequate for your work.
  • Page 8 TLV and PEL values are as of April 2006. Always check Material Know Act of 1986 and of 40CFR 370 and 372. Safety Data Sheet (MSDS) with product or on the Lincoln Electric website at http://www.lincolnelectric.com (b) The PEL for chromium (VI) is .005 milligrams per cubic meter as an 8 hour time weighted average.
  • Page 9 POWER FEED 84, POWER FEED 84 DUAL NOTES viii...
  • Page 10 POWER FEED 84, POWER FEED 84 DUAL TABLE OF CONTENTS MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ....................................ii-viii Installation, Operation, Accessories, Maintenance ..................... See IM10178 Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F...
  • Page 11 Power Feed 84 Dual Function And Input ........
  • Page 12 POWER FEED 84 DUAL FUNCTION AND INPUT The Power Feed 84 is a four drive roll, digitally controlled, modular wire feeder that operates on 40 VDC input power. Network communi- cations (Arclink CAN), PC board power (40 VDC) and electrode voltage feedback (LED 67) are all transmitted and received through the five pin Arclink receptacle located on the right side of the machine.
  • Page 13 POWER FEED 84, POWER FEED 84 DUAL THEORY OF OPERATION Figure E.3 - Wire drive PC boards and voltage sense boards OUTPUT FEED PLATE CONTACTOR (LEFT) (OPTIONAL) ELECTRODE IN WIRE DRIVE MOTOR AND USER INTERFACE TACH BOARD (LEFT) (BENCH MODELS)
  • Page 14 POWER FEED 84, POWER FEED 84 DUAL THEORY OF OPERATION Figure E.4 - Output contactors and wire drive motors OUTPUT FEED PLATE CONTACTOR (LEFT) (OPTIONAL) ELECTRODE IN WIRE DRIVE MOTOR AND USER INTERFACE TACH BOARD (LEFT) (BENCH MODELS) GAS FLOW...
  • Page 15 POWER FEED 84, POWER FEED 84 DUAL THEORY OF OPERATION Figure E.5 - User interface board OUTPUT FEED PLATE CONTACTOR (LEFT) (OPTIONAL) ELECTRODE IN WIRE DRIVE MOTOR AND USER INTERFACE TACH BOARD (LEFT) (BENCH MODELS) GAS FLOW SENSOR (LEFT) 5 PIN...
  • Page 16 The STATUS LED is designed to blink a green code if a fault should occur. The Power Feed 84 single bench and the Power Feed 84 dual bench do not have User Interface Boards in the control box. On these models the User Interface Board circuitry is on the feed head board located in the wire drive box.

  • Page 17: Table Of Contents

    POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ....................Section F How to Use Troubleshooting Guide ..........F-2 PC Board Troubleshooting Procedures .

  • Page 18: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 19: Pc Board Troubleshooting Procedures

    POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES 4. Test the machine to determine if the failure symptom has been WARNING corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

  • Page 20: Troubleshooting Guide

    Purge Switch Test. Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 21 See Operation section of operator’s manual for detailed operation. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 22 5. The solenoid has failed. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 23 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 24 2. The gun may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 25 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 26 Wire Drive PC Board(s) Removal And Replacement Procedure. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F-10...
  • Page 27 2. Verify that the gears are free of debris and dirt. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F-11...
  • Page 28 Reflash system software. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. F-12...

  • Page 29: Case Cover Removal And Replacement Procedure

    CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
  • Page 30 REMOVAL PROCEDURE plug J83 from the front board. The bypass capacitor will still be 1. Remove input power from the Power Feed 84 wire feeder. connected to the roof panel by a threaded terminal. See Figure F.3. See Wiring Diagram.
  • Page 31 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.2 – Wire drive PC board plug locations Figure F.3 – Threaded terminals location THREADED WIRE DRIVE TERMINAL POST PC BOARD (FRONT BOARD)
  • Page 32 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.4 – Case side mounting screws CASE SIDE MOUNTING SCREWS (TWO ON EACH SIDE) REPLACEMENT PROCEDURE 1. Using a 5/16” nutdriver, attach the two screws securing the left case side.

  • Page 33: Tach Feedback Test

    TACH FEEDBACK TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 34 TACHOMETER (ONE ON EACH MOTOR) PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure, for case sides. 3. Locate the tachometer. See Figure F.5. NOTE: There are two tachometers, one on each side of the machine.
  • Page 35 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR TACH FEEDBACK TEST (continued) Figure F.6 – Plug J84 on wire drive PC board F-19...
  • Page 36 POWER FEED 84, POWER FEED 84 DUAL NOTES F-20...

  • Page 37: Cold Inch/Feed Gas Purge Switch Test

    COLD INCH/FEED GAS PURGE SWITCH TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
  • Page 38 GAS PURGE SWITCH (ONE SWITCH ON EACH SIDE) PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure, for case sides. 3. Locate the cold inch/feed gas purge switch. See Figure F.7.
  • Page 39 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR COLD INCH/FEED GAS PURGE SWITCH TEST (continued) Figure F.8 – Wire drive PC board leads F-23...
  • Page 40 POWER FEED 84, POWER FEED 84 DUAL NOTES F-24...

  • Page 41: Voltage Sense Board(S) Test

    VOLTAGE SENSE BOARD(S) TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 42 11. Check the continuity of lead 67 from the conductor block to plug PROCEDURE J1 pin 3 on the voltage sense board. See Figure F.11. See 1. Remove input power from the Power Feed 84 wire feeder. Wiring Diagram. 2. Perform the Case Cover Removal Procedure, for case sides.
  • Page 43 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR VOLTAGE SENSE BOARD(S) TEST (continued) Figure F.10 – Gun adapter cover removal SCREW ADAPTER COVER Figure F.11 – Voltage sense board plugs M19540-3 267B F-27...
  • Page 44 POWER FEED 84, POWER FEED 84 DUAL NOTES F-28...

  • Page 45: Gas Solenoid(S) Test

    GAS SOLENOID(S) TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 46 Figure F.12 – Gas solenoid location GAS SOLENOID PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure. 3. Locate the gas solenoid to be tested. See Figure F.12. NOTE: There are two gas solenoids, one on each side of the machine.
  • Page 47 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR GAS SOLENOID(S) TEST (continued) Figure F.13 – Gas solenoid leads F-31...
  • Page 48 POWER FEED 84, POWER FEED 84 DUAL NOTES F-32...

  • Page 49: User Interface And Usb Board Test

    USER INTERFACE AND USB BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
  • Page 50 (USER INTERFACE BOARD LOCATED ON REAR OF UI CASE FRONT ASSEMBLY) PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Using a 5/16” nutdriver, remove the four screws securing the UI case front assembly to the machine. See Figure F.14.
  • Page 51 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR USER INTERFACE AND USB BOARD TEST (continued) Figure F.15 – Optional USB PC board location OPTIONAL USB PC BOARD Table F.1 – User interface board test points DESCRIPTION TEST POINTS...
  • Page 52 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR USER INTERFACE AND USB BOARD TEST (continued) Figure F.16 – User interface board lead locations 500C(–) 541C 542C USER INTERFACE BOARD (SOLDER SIDE) Figure F.17 – Optional USB board lead locations...

  • Page 53: Wire Drive Pc Board(S) Test

    WIRE DRIVE PC BOARD(S) TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 54 Figure F.18 – Wire drive PC board location WIRE DRIVE BOARDS PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure. 3. Locate the wire drive PC board. See Figure F.18.
  • Page 55 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR WIRE DRIVE PC BOARD(S) TEST (continued) Table F.3 – Wire drive PC board test points LEAD NUMBERS DESCRIPTION TEST POINTS EXPECTED READING CONDITIONS FRONT REAR BOARD BOARD INPUT POWER APPLIED...
  • Page 56 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR WIRE DRIVE PC BOARD(S) TEST (continued) Figure F.19 – Wire drive PC board leads Figure F.20 – Wire drive PC board lead locations F-40...

  • Page 57: Wire Drive Motor(S) Test

    WIRE DRIVE MOTOR(S) TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 58 PROCEDURE motor does not run or vary in speed with changes in armature 1. Remove input power from the Power Feed 84 wire feeder. voltage, the wire drive motor may be faulty. 2. Perform the Case Cover Removal Procedure, for case sides.

  • Page 59: Optional Output Contactor Test

    (ELECTRODE TO FEEDPLATE AND GOUGING TO OUTPUT TERMINAL) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
  • Page 60 11. When the contactor is not activated, there should be very high PROCEDURE resistance across the contactor terminals - more than 500,000 1. Remove input power from the Power Feed 84 wire feeder. ohms. 2. Perform the Case Cover Removal Procedure, for case sides.
  • Page 61 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR OPTIONAL OUTPUT CONTACTOR TESTS (ELECTRODE TO FEEDPLATE AND GOUGING TO OUTPUT TERMINAL) (continued) Figure F.23 – Red and black contactor leads LEAD CONTACTOR CONTACTS BLACK LEAD F-45...
  • Page 62 POWER FEED 84, POWER FEED 84 DUAL NOTES F-46...

  • Page 63: Cold Inch/Feed Gas Purge Switch Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 64 GAS PURGE SWITCH (ONE SWITCH ON EACH SIDE) REMOVAL PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure. 3. Locate the cold inch/feed gas purge switch. See Figure F.24. 4. Label and disconnect leads 535, 586 and 579 from the right side cold inch/feed gas purge switch or leads 635, 686 and 679 from the left side cold inch/feed gas purge switch.
  • Page 65 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR COLD INCH/FEED GAS PURGE SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.25 – Cold inch/feed gas purge switch removal SIDE TABS REPLACEMENT PROCEDURE 1. Carefully position new switch in machine and press firmly to seat switch in it’s mount.
  • Page 66 POWER FEED 84, POWER FEED 84 DUAL NOTES F-50...

  • Page 67: Voltage Sense Board(S) Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 68 M19540-3 STAND-OFF’S (3) REMOVAL PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure. 3. Label and disconnect plugs J1 and J2 from the right voltage sense board and/or plugs J1(A) and J2(A) from the left voltage sense board.
  • Page 69 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR VOLTAGE SENSE BOARD(S) REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.27 – Voltage sense board location VOLTAGE SENSE BOARD (ONE ON EACH SIDE) REPLACEMENT PROCEDURE 1. Carefully position new voltage sense board in machine and press firmly to mount on the three stand-offs.
  • Page 70 POWER FEED 84, POWER FEED 84 DUAL NOTES F-54...

  • Page 71: Gas Solenoid(S) Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 72 GAS SOLENOID GAS SOLENOID REMOVAL PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure. 3. Label and disconnect leads from the gas solenoid (652 and 653 for left gas solenoid, 552 and 553 for right gas solenoid). See Figure F.28.
  • Page 73 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR GAS SOLENOID(S) REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.29 – Gas solenoid removal GAS SOLENOID FLAT WASHER REPLACEMENT PROCEDURE 1. Carefully position the new gas solenoid(s) into the rear panel of the machine.
  • Page 74 POWER FEED 84, POWER FEED 84 DUAL NOTES F-58...

  • Page 75: User Interface Board Removal And Replacement Procedure

    USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
  • Page 76 MOUNTING SCREWS REMOVAL PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Using a 5/16” nutdriver, remove the four screws securing the UI case front assembly to the machine. See Figure F.30. 3. Label and disconnect plug J31 from the user interface board. See Figure F.31.
  • Page 77 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.31 – User interface board (solder side) MOUNTING SCREWS (4) Figure F.32 – Knob removal FELT WASHER KNOB (3) BUTTON COVER (12)
  • Page 78 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position new user interface board on back of nameplate. 2. Using a phillips screwdriver, attach the four screws and washers securing the user interface board to the nameplate.

  • Page 79: Optional Usb Pc Board Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 80 MOUNTING SCREWS REMOVAL PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Using a 5/16” nutdriver, remove the four screws securing the UI case front assembly to the machine. See Figure F.33. 3. Label and disconnect plugs J1, J2 and J3 from the optional USB PC board.
  • Page 81 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR OPTIONAL USB PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.34 – USB PC board plug locations MOUNTING SCREW LOCATIONS (4) REPLACEMENT PROCEDURE 1. Carefully place new optional USB PC board into machine.
  • Page 82 POWER FEED 84, POWER FEED 84 DUAL NOTES F-66...

  • Page 83: Wire Drive Pc Board Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 84 MOUNTING NUTS (4) REMOVAL PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure. 3. Using a 3/8” nutdriver, remove the four nuts securing the wire drive PC board to the roof panel. Repeat step for the other board.
  • Page 85 “dual” wire drives, they are just wire drive PC boards and all have the same software. So a wire drive PC board from a single power feed 84 can be put into a dual power feed 84 and vice versa.
  • Page 86 POWER FEED 84, POWER FEED 84 DUAL NOTES F-70...

  • Page 87: Motor And Gear Box Assembly Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 88 10. Label and disconnect plug 19 from the left tachometer and plug 9 REMOVAL PROCEDURE from the right tachometer. See Wiring Diagram. 1. Remove input power from the Power Feed 84 wire feeder. 11. Using needle-nose pliers, loosen hose clamp securing gas hose to 2. Perform the Case Cover Removal Procedure.
  • Page 89 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR MOTOR AND GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.37 – Top motor support and circuit breaker location MOUNTING SCREW (THREE FOR EACH ASSEMBLY) MOTOR TOP SUPPORT SPACERS...
  • Page 90 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR MOTOR AND GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.38 – Gun adapter cover removal SCREW ADAPTER COVER Figure F.39 – Heavy black lead removal BOLT HEAVY BLACK...
  • Page 91 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR MOTOR AND GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.40 – Gas hose location GAS HOSE & HOSE CLAMP Figure F.41 – Lead location LEAD #67B OR #167B...
  • Page 92 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR MOTOR AND GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.42 – Motor and gear box assembly mounting screws MOUNTING SCREWS Figure F.43 – Motor and gear box assembly mounting screws...
  • Page 93 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR MOTOR AND GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.44 – Removing drive motor from gearbox GEAR BOX GASKET DRIVE MOTOR ALLEN TYPE MOUNTING SCREWS (6) Figure F.45 – Removing wire drive from gear box...
  • Page 94 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR MOTOR AND GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.46 – Removing tachometer from motor MOTOR TACHOMETER ALLEN TYPE MOUNTING SCREWS F-78...
  • Page 95 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR MOTOR AND GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) 10. Connect the gas hose to the gun adapter. Repeat this step for REPLACEMENT PROCEDURE each motor and gear box assembly if necessary.
  • Page 96 POWER FEED 84, POWER FEED 84 DUAL NOTES F-80...

  • Page 97: Optional Output Contactor(S) Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 98 MOUNTING NUT BLACK LEAD REMOVAL PROCEDURE 1. Remove input power from the Power Feed 84 wire feeder. 2. Perform the Case Cover Removal Procedure. 3. Perform the Motor and Gear Box Assembly Removal Procedure, to remove both motor and gear box assemblies.
  • Page 99 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR OPTIONAL OUTPUT CONTACTOR(S) REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.48 – Contactor leads LEAD BLACK LEAD Figure F.49 – Contactor mounting bolts WASHER CONTACTOR MOUNTING BOLTS F-83...
  • Page 100 POWER FEED 84, POWER FEED 84 DUAL TROUBLESHOOTING AND REPAIR OPTIONAL OUTPUT CONTACTOR(S) REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position new contactor into machine. 2. Using a 5/16” nutdriver, attach the two bolts and washers securing contactor to rear panel while holding square nut in place.
  • Page 101 POWER FEED 84, POWER FEED 84 DUAL NOTES F-85...

  • Page 102: Retest After Repair

    1. Once the repairs have been completed, the feeder must be connected to a Powerwave power source. 2. Make certain the wire feeds and the speed is adjustable. 3. Make sure the Power Feed 84 communicates with the compatible Powerwave power source. F-86...
  • Page 103 POWER FEED 84, POWER FEED 84 DUAL DIAGRAMS TABLE OF CONTENTS - DIAGRAMS SECTION - Diagrams ..........................Section G Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2...
  • Page 104 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
  • Page 105 LEFT SIDE OF MACHINE OPTIONAL GAS NOT USED FLOW SENSOR P6 / J6 CB1 3A BROWN (RIGHT) BLACK BYPASS BLUE CAPACITOR 500B 500S JUMPER LEAD TO J83 ON PAGE 2 VOLTAGE SENSE 540B 542B SELECT P.C. BOARD DUAL (RIGHT) 3218 542A DUAL 540A...
  • Page 106 LEFT SIDE OF MACHINE OPTIONAL GAS FLOW SENSOR P16 / J16 USER INTERFACE CB11 3A PC BOARD BROWN (LEFT) BLACK BYPASS BLUE CAPACITOR 600B 600S 1 2 3 4 542C 540C JUMPER LEAD TO J82 541C 500C ON PAGE 1 640B 642B DUAL...
  • Page 107 OPTIONAL LEFT SIDE OF MACHINE ARC GOUGE CONTACTOR CONNECTION OPTIONAL GAS FLOW SENSOR P6 / J6 USER INTERFACE PC BOARD BROWN BYPASS CB1 3A BLACK CAPACITOR BLUE 500B 500S 1 2 3 4 542C 540C 541C 500C VOLTAGE SENSE 540B 542B SELECT P.C.
  • Page 108 LEFT SIDE OF MACHINE OPTIONAL GAS NOT USED FLOW SENSOR P6 / J6 CB1 3A BROWN (RIGHT) BLACK BYPASS BLUE CAPACITOR 500B 500S JUMPER LEAD TO J83 ON PAGE 2 VOLTAGE SENSE 540B 542B SELECT P.C. BOARD DUAL (RIGHT) 3218 542A DUAL 540A...
  • Page 109 LEFT SIDE OF MACHINE OPTIONAL GAS FLOW SENSOR P16 / J16 USER INTERFACE CB11 3A PC BOARD BROWN (LEFT) BLACK BYPASS BLUE CAPACITOR 600B 600S 1 2 3 4 542C 540C JUMPER LEAD TO J82 541C 500C ON PAGE 1 640B 642B DUAL...
  • Page 110 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
  • Page 111 10.56 5.94 9.06 HEAVY DUTY 14.33 8.36 WIRE REEL STAND 25.17 16.42 12.71 12.18 11.00 24.45 15.46 27.93 14.08 7.79 STANDARD DUTY WIRE REEL STAND 13.28 10.01 21.67 11.00 15.46 23.62 18.04 5/16-18 UNC-2B 1.50 3.78 1.50 (8 PLACES) 11.58 1.03 WIRE DRIVE HOUSING...
  • Page 112 10.59 2.99 19.71 5.94 1.09 HEAVY DUTY WIRE REEL STAND 25.17 16.42 12.71 15.19 6.85 6.81 27.07 22.46 30.56 19.61 7.80 STANDARD DUTY WIRE REEL STAND 13.28 10.01 15.19 6.85 6.81 24.29 22.46 26.24 27.28 4.08 1.50 1.50 13.22 5/16-18 UNC-2B WIRE DRIVE (8 PLACES) HOUSING...
  • Page 113 6.88 3.62 8.66 6.00 1/4-20 UNC-2B (4 PLACES) 9.44 7.00 4.25 1.72 1.59 1.22 (4 PLACES) 2.68 1.13 3.95 1.95 A.01 M24856...

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