Lincoln Electric LN-7 Service Manual
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Lincoln Electric LN-7 Service Manual

Lincoln Electric LN-7 Service Manual

Gma wire feeder
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LN-7
GMA WIRE FEEDER
™
For use with machines having Code Numbers:
9100, 9168, 9386, 9643, 9644, 9796, 9928, 9929, 9931,
10225, 10325, 10363, 10364, 10737
SERVICE MANUAL
LN-7™ GMA shown with optional K417 digital meter kit and
K418 GMA timer kit.
SVM106-B
| Issue D ate 12, Jul
© Lincoln Global, Inc. All Rights Reserved.
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: 9100, 9168, 9386, 9643, 9644, 9796, 9928, 9929, 9931, 10225, 10325, 10363, 10364, 10737 SERVICE MANUAL LN-7™ GMA shown with optional K417 digital meter kit and K418 GMA timer kit. SVM106-B | Issue D ate 12, Jul...
  • Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. LN-7™ GMA WIRE FEEDER...
  • Page 4 During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101. 6.j. Do not use a welding power source for pipe thawing. Refer to http://www.lincolnelectric.com/safety for additional safety information. LN-7™ GMA WIRE FEEDER...
  • Page 5 4. Garder tous les couvercles et dispositifs de sûreté à leur place. talons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. LN-7™ GMA WIRE FEEDER...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 Screening of the entire welding installation may be considered for special applica- tions. 1 _________________________ 1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod- uct standard for arc welding equipment.” LN-7™ GMA WIRE FEEDER...
  • Page 8 Parts Manual ..............P-283 LN-7™ GMA WIRE FEEDER...

  • Page 9: Table Of Contents

    Shielding Gas Hookup ..............A-23 LN-7™ GMA WIRE FEEDER...
  • Page 10 INSTALLATION TECHNICAL SPECIFICATIONS – LN-7™ and LN-7™ GMA INPUT VOLTAGE Supplied by power source: 115 VAC, 50/60 Hz, 2.5 Amps WIRE FEED SPEED LN-7™ GMA 75 to 700 in. per minute (1.90 to 17.8 m/min) LN-7™ 50 to 500 in. per minute (1.27 to 12.7 m/min) WIRE DIAMETERS...

  • Page 11: Installation

    TABLE A.1 - LN-7™ GMA CONNECTION DIAGRAMS Figure # Power Source LN-7™ GMA To DC-400, DC-250 and CV/CVI Power Sources With Terminal Strip - Connection Diagram LN-7™ GMA To Pulsed Power 500 - Connection Diagram LN-7™ GMA To CV/CVI Power Sources With 14 Pin Amphenol Connector - Connection Diagram LN-7™...
  • Page 12 If lead #21 is extended to work, do not con- of the LN-7™ case. Connect the electrode cable to nect leads to terminal #21 on terminal strip. For the brass conductor block on the front of the gear- K584, K594 or K480 cables connect the 14 pin box using the 1/2-13 x .75 bolt provided.
  • Page 13 Remove the screws holding the clamp to the base of the wire reel mounting assembly, put the input cable assembly under the clamp and reinstall the screws. FIGURE A.2 – STRAIN RELIEF CLAMP CONTROL CABLE STRAIN RELIEF CLAMP ELECTRODE CABLE LN-7™ GMA WIRE FEEDER...
  • Page 14 INSTALLATION FIGURE A.3 – LN-7™ & LN-7™ GMA TO DC-400, DC-250 AND CV/CVI POWER SOURCES WITH TERMINAL STRIP - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL – CLEVELAND, OHIO U.S.A...
  • Page 15 INSTALLATION FIGURE A.4 – LN-7™ & LN-7™ GMA TO PULSED POWER 500 - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL – CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 16 INSTALLATION FIGURE A.5 – LN-7™ & LN-7™ GMA TO CV/CVI POWER SOURCES WITH 14 PIN AMPHENOL CONNECTOR - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL – CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 17 INSTALLATION FIGURE A.6 – LN-7™ & LN-7™ GMA TO CV/CVI POWER SOURCES WITH TWIST-MATE CONNECTOR AND 14 PIN AMPHENOL/REMOTE CONTROL - CONNECTION DIAGRAM TURN OFF INPUT POWER WARNING TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH AT THE FUSE BOX BEFORE CONNECTING THE WIRE FEEDER.
  • Page 18 INSTALLATION A-10 A-10 FIGURE A.7 – LN-7™ & LN-7™ GMA TO CV/CVI POWER SOURCE (K867/K775) - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL – CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 19 INSTALLATION A-11 A-11 FIGURE A.8 – LN-7™ & LN-7™ GMA TO R3S-250 OR R3S-325 - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL – CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 20 INSTALLATION A-12 A-12 FIGURE A.9 – LN-7™ & LN-7™ GMA TO SAM MOTOR GENERATOR OR ENGINE WELDER - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 21 INSTALLATION A-13 A-13 FIGURE A.10 – LN-7™ & LN-7™ GMA TO DC-600 - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL – CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 22 INSTALLATION A-14 A-14 FIGURE A.11 – LN-7™ & LN-7™ GMA TO R3S-400, 600, OR 800 - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 23 INSTALLATION A-15 A-15 FIGURE A.12 – LN-7™ & LN-7™ GMA TO MOST LINCOLN MOTOR GENERATORS - CONNECTION DIAGRAM TURN INPUT POWER OFF WARNING BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL CLEVELAND, OHIO U.S.A LN-7™ GMA WIRE FEEDER...
  • Page 24 INSTALLATION A-16 A-16 FIGURE A.13 – LN-7™ & LN-7™ GMA TO WP250 OR G9 PRO - CONNECTION DIAGRAM LN-7 GMA TO WP250 G9 TURN INPUT POWER OFF WARNING CAUTION PRO: ANY INCREASE OF THE BEFORE CONNECTING THE HIGH IDLE ENGINE RPM BY LN-7 GMA WIRE FEEDER.
  • Page 25 INSTALLATION A-17 A-17 FIGURE A.14 – LN-7™ & LN-7™ GMA TO RANGER 9 – CONNECTION DIAGRAM WARNING WARNING DO NOT OPERATE WITH KEEP GUARDS IN PLACE. PANELS OPEN. KEEP AWAY FROM MOVING DISCONNECT NEGATIVE (-) PARTS. BATTERY LEAD BEFORE SERVICING. ONLY QUALIFIED PERSONS...
  • Page 26 INSTALLATION A-18 A-18 FIGURE A.15 – LN-7™ & LN-7™ GMA TO RANGER 10-LX – CONNECTION DIAGRAM WARNING WARNING DO NOT OPERATE WITH KEEP GUARDS IN PLACE. PANELS OPEN. KEEP AWAY FROM MOVING DISCONNECT NEGATIVE (-) PARTS. BATTERY LEAD BEFORE SERVICING. ONLY QUALIFIED PERSONS...
  • Page 27 INSTALLATION A-19 A-19 FIGURE A.16 – LN-7™ & LN-7™ GMA TO POWER SOURCES WITH NO OUTPUT CONTACTOR - CONNECTION DIAGRAM LN-7™ GMA WIRE FEEDER...
  • Page 28 INSTALLATION A-20 A-20 FIGURE A.17 – LN-7™ & LN-7™ GMA TO POWER SOURCES WITH CONTACTOR AND NO TERMINAL STRIP - CONNECTION DIAGRAM WARNING TURN INPUT POWER OFF BEFORE CONNECTING THE LN-7 GMA WIRE FEEDER. ELECTRIC SHOCK CAN KILL CLEVELAND, OHIO U.S.A...

  • Page 29: Work Cable

    BLOCK in the front panel of the LN-7™ and into the brass conductor block on the front of the gearbox. See Figure A.18. Make sure it is all the way in and GUN CABLE tighten the hand wheel.

  • Page 30: Water Connections (For Water Cooled Guns

    (FOR WATER COOLED GUNS) and outlet on the back of the LN-7™. Connect the other ends of these hoses to the appropriate ports The LN-7™ or LN-7™ GMA must have a K527 on your water cooling units.

  • Page 31: Shielding Gas Hookup

    GMA or LN-7™ with Optional K494 Gas from the flow valve to the gas inlet fitting of the LN-7™ Solenoid Installed) GMA or the K494 Gas Solenoid Valve Kit installed on the LN-7™.
  • Page 32 NOTES A-24 A-24 LN-7™ GMA WIRE FEEDER...
  • Page 33 Optional Flux Tank Loading ............B-15 LN-7™ GMA WIRE FEEDER...

  • Page 34: Operation

    SAFETY INSTRUCTIONS speed wire feeder is specifically equipped for gas metal arc welding using flux-cored Outershield WARNING electrodes and solid wire. The LN-7™ GMA is also suitable for self-shielded flux-cored Innershield electrodes, submerged arc welding (if constant ELECTRIC SHOCK can kill.

  • Page 35: Recommended Processes And Equipment

    Both are recommended for use with constant and 0.045 in. through 7/64 in. (1.2 through 2.8 mm) voltage power sources such as the Idealarc DC- cored. 250, 400, or 600, or CV types. The LN-7™ GMA is FIGURE B.1 – WIRE FEEDER CONTROLS PREFLOW POSTFLOW...

  • Page 36: Circuit Protection

    An “A” after the size indicates aluminum The frame of the LN-7™ wire feed unit is grounded to wire. Remove the rolls from the kit and wipe them the frame of the power source by a lead in the control clean.
  • Page 37 OPERATION FIGURE B.2 – INSTALLING DRIVE ROLLS ON A TWO-ROLL FEEDER LN-7™ GMA WIRE FEEDER...
  • Page 38 7. Install the middle guide tube, but do not tighten at this time. When installing a 0.035” middle guide tube the larger radius should be aligned towards the drive roll. Slide the guide tube up against the drive roll. LN-7™ GMA WIRE FEEDER...
  • Page 39 FIGURE B.3 – INSTALLING DRIVE ROLLS ON A FOUR-ROLL FEEDER CLAMPING COLLAR DRIVE ROLL SPACER (IF HALVES REQUIRED) OUTPUT SHAFT LARGE GUIDE TUBE DETAIL RADIUS OUTGOING DRIVE GUIDE TUBE ROLL OUTGOING GUIDE TUBE INSERT MIDDLE GUIDE IDLE TUBE ROLL SMALL RADIUS LN-7™ GMA WIRE FEEDER...

  • Page 40: Idle Roll Pressure Setting

    3. Set both idle roll tensions to this setting. Engage both idle rolls before welding. For most applica- tions, best wire feeding will occur when both idle roll pressures are set the same. LN-7™ GMA WIRE FEEDER...

  • Page 41: Wire Loading

    FIGURE B.5 – INSTALLING A 30 LB READI-REEL ® PACKAGE 2 IN. O.D. SPINDLE ADAPTER RETAINING SPRING BRAKE HOLDING GROOVES READI-REEL INSIDE CAGE WIRES THREADED LOCKING COLLAR LN-7™ GMA WIRE FEEDER...
  • Page 42 “birdnest”.) 3. Insert the free end through the incoming guide tube. 4. Press the gun trigger and push the electrode into the drive roll. LN-7™ GMA WIRE FEEDER...
  • Page 43 TIE WIRE 7. Tighten the cover as much as possible by hand. DO NOT hammer on the spinner nut arms. REEL SPRING LOADED LN-7™ GMA WIRE FEEDER...
  • Page 44 Keep the reel from turning and tighten the cen- ter clamping nut securely. 8. Thread the exposed end of the electrode into the wire feeder until it touches the drive rolls. Actuate the gun trigger and feed the electrode through the system. LN-7™ GMA WIRE FEEDER...

  • Page 45: Acceleration Setting

    Set the side of the LN-7™ or LN-7™ GMA. To change the open circuit voltage to approximately 2 volts higher acceleration on earlier control PC boards, reconnect than the desired procedure voltage.

  • Page 46: Making A Weld

    3/8 in. of the end of the contact tip. If using cored nection block inside the LN-7™. To match these volt- wire, cut the electrode within 3/4 in. of the extension age readings, the #21 lead should be extended direct- guide.
  • Page 47 If the magnetic material is not removed it will gather around the nozzle of the gun and impede or shut off the flux flow when making relatively long welds or welding continuously. The magnetic particles can also cause porosity in the weld. LN-7™ GMA WIRE FEEDER...
  • Page 48 NOTES B-16 B-16 LN-7™ GMA WIRE FEEDER...
  • Page 49 Attaching the Wire Reel Stand ............C-5 LN-7™ GMA WIRE FEEDER...
  • Page 50 Adapter Cable for Control Cable to Terminal Strip Power Source K1803-1 Work and Wire Feeder Power Cables Package *Magnum GMA welding guns require a K466-1 connector for use with the LN-7™ GMA wire feeder. **A detailed description of each item is given later in this section.

  • Page 51: Accessories

    The current draw must NOT The kit is available for those applications where the exceed 1/4 ampere. LN-7™ or LN-7™ GMA is used for higher speed, fine wire feeding (0.023 in. to 0.045 in. wire sizes) where CAUTION there is a tendency for the electrode to overrun at the end of the weld causing “sticking”...

  • Page 52: K418 Gma Timer Kit

    This kit is available to provide the following functions: The K320 flux tank is available to permit the LN- 7™ or LN-7™ GMA to be used for submerged arc 1. Preflow Control – Provides flow of shielding gas to welding.

  • Page 53: Attaching The Wire Reel Stand

    (See Figure C.2). Install the proper insulated nozzle extension and contact tip for the stickout and electrode This kit is factory installed on the K440-1 LN-7™ GMA. size being used. K494 LN-7™ GAS SOLENOID KIT For welding with 7/64 in. Innershield electrode, use a K115-3/32 with an M11474-120 nozzle or a K115-45- (STANDARD ON LN-7™...
  • Page 54 NOTES LN-7™ GMA WIRE FEEDER...
  • Page 55 Periodic Maintenance ..............D-2 Gun Cable Connector Requirements To Permit Connection To LN-7™ GMA And LN-7™ Wire Feeders .D-4 Sequence of Operation .

  • Page 56: Maintenance

    Every year inspect the gearbox and coat the gear teeth with a moly-disulfide filled grease. Do not use graphite grease. Every six months check the motor brushes. Replace them if they are less than 1/4 in. long. LN-7™ GMA WIRE FEEDER...
  • Page 57 .005 to .050 in. to allow a small amount of air to escape when the equipment is being used. If this end piece is badly corroded, replace it with a new piece. LN-7™ GMA WIRE FEEDER...
  • Page 58 .045 & .052 (1.1 & 1.3) .062 [1/16” (1.6 mm) Drill] connected to the LN-7™ GMA and LN-7™. .023-.035 (0.6-0.9) .055 [(1.4 mm) #54 Drill] FIGURE D.1 – LN-7™ CONNECTORS All dimensions in inches and (millimeters).

  • Page 59: Sequence Of Operation

    MAINTENANCE LN-7™ SEQUENCE OF OPERATION (Optional Timer Kit not Installed) Turn on Power Source Press Gun Trigger Closes 524-525 Energizes 1 CR Closes 31-7A circuit Closes 2-4 Circuit 115V AC input power is applied to SCR Energizes welder Energizes aux. equipment...

  • Page 60: Major Component Locations

    FIGURE D.3 - MAJOR COMPONENT LOCATIONS 1. Control Box Assembly 2. Rear Panel Assembly 3. Wire Drive Assembly 4. Cover And Hinge Assembly 5. Case Front Assembly 6. Base Plate Assembly 7. Analog/Digital Voltmeter Kit 8. Water Solenoid Kit LN-7™ GMA WIRE FEEDER...
  • Page 61 8.8 VAC CIRCUIT TRIGGER 115 VAC CONTROL BREAKER TRANS- BOARD FORMER FROM DIODE 24 VAC 115 VAC 24 VDC WELDING RECTIFIER TO WELDING CONTROL POWER NETWORK CONTACTOR RELAY SUPPLY TRIGGER WIRE GROUND SPEED LEAD CONTROL PROTECTOR LN-7™ GMA WIRE FEEDER...
  • Page 62 CONTROL PROTECTOR GENERAL DESCRIPTION CONTROL CIRCUIT OPERATION The LN-7™ GMA wire feeder is available in two POWER INPUT CIRCUITS versions; a two-roll and a four-roll wire feeder. The operation of the two versions is virtually identical. The LN-7™ GMA receives 115 VAC power from the The following description of the operation of the wire welding supply.
  • Page 63 The three sets of contacts in the relay close and energize the multiple functions of the wire feeder. See Figure E.3. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion LN-7™ GMA WIRE FEEDER...
  • Page 64 On a four-roll wire feeder, the gearbox also splits the drive power to two separate drive rolls. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion LN-7™ GMA WIRE FEEDER...
  • Page 65 8.8 VAC signal from the postflow by controlling the timing of the gas trigger transformer. See Figure E.5. solenoid. See Figure E.5. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion LN-7™ GMA WIRE FEEDER...
  • Page 66 CURRENT LIMITING CIRCUIT The current limiting circuit limits the current that is Protective circuits are designed in to the LN-7™ sent to the feed motor. A precision resistor in line GMA to detect trouble and shut down the wire feeder with the feed motor produces a voltage drop that is before any damage to the feeder can result.
  • Page 67 SCR will remain on. When the anode to cathode current drops below a minimum value, Since the wire speed of the LN-7™GMA is called holding current, the SCR will shut off. This controlled by SCR circuitry, a basic understanding normally occurs as the AC supply voltage passes of how an SCR functions is important.
  • Page 68 NOTES LN-7™ GMA WIRE FEEDER...
  • Page 69 Retest After Repair ..............F-56 LN-7™ GMA WIRE FEEDER...

  • Page 70: Troubleshooting And Repair

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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 71: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 72 * (J4 on earlier models) CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 73 Replacement procedure. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 74 OCV. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 75 Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 76 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 77 Board. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 78 “contaminated”. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 79 Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. LN-7™ GMA WIRE FEEDER...
  • Page 80 NOTES F-12 F-12 LN-7™ GMA WIRE FEEDER...

  • Page 81: Control Relay Test

    CONTROL RELAY 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 82 Terminals the table. Repeat step 4 for all sets of contacts A&B A&B listed. Terminals Energized De-energized 6. Perform the Control Relay Replacement Open Closed Procedure. Closed Open Open Closed Closed Open Open Closed Closed Open LN-7™ GMA WIRE FEEDER...

  • Page 83: Trigger Transformer Test

    TRIGGER TRANSFORMER 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 84 115 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 voltage for a good trans- former is 24 VAC. LN-7™ GMA WIRE FEEDER...

  • Page 85: Control Cable Continuity Test

    CONTROL CABLE CONTINUITY 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 86 1.0 Ohm, the cable is faulty and should be replaced. If the resistance between conductors is less than 0.5 MOhm, the cable is faulty and should be replaced. TABLE F.2 – CONTROL CABLE PIN AND LEAD DESIGNATIONS SIX PIN AMPHENOL LEAD NUMBERS FOURTEEN PIN WIRE FEEDER END MACHINE END AMPHENOL MACHINE END CASE GROUND LN-7™ GMA WIRE FEEDER...

  • Page 87: Removal And Replacement Procedures

    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 3. Remove the nut and lockwasher holding the 5. Solder the three wires to the new potentiometer potentiometer to the case of the wire feeder. on the corresponding terminals from which they Remove the potentiometer through the inside of were removed. the case. LN-7™ GMA WIRE FEEDER...
  • Page 89 Also, the motor or the con- 8. Reinstall the cover onto the control box using trol board may be faulty. the four hex head bolts. LN-7™ GMA WIRE FEEDER...
  • Page 90 NOTES F-22 F-22 LN-7™ GMA WIRE FEEDER...

  • Page 91: Circuit Breaker Removal And Replacement Procedure

    CIRCUIT BREAKER 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 92 3. Remove the retaining nut that secures the cir- 6. Reinstall the cover on the wire feeder using four cuit breaker to the panel of the wire feeder. hex head screws. Remove the circuit breaker from the wire feed- LN-7™ GMA WIRE FEEDER...

  • Page 93: Ground Lead Protector Push Button 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 94 See Figure F.5. 7. Reinstall the cover on the control box using four 3. Unsolder the two leads from the back of the hex head screws. push button. LN-7™ GMA WIRE FEEDER...

  • Page 95: Trigger Transformer Removal And Replacement Procedure

    TRIGGER TRANSFORMER 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 96 3. Remove the two phillips head screws that 6. Reinstall the cover on the control box using four attach the transformer to the case of the control hex head screws. box. Remove the old transformer from the wire feeder. LN-7™ GMA WIRE FEEDER...

  • Page 97: Ground Lead Protector Reed 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 98 4. Slide the reed switch out of the loop formed by 8. Reinstall the cover on the wire feeder using four the ground wire and remove the reed switch hex head screws. from the wire feeder. Do not undo the loop in the ground wire. LN-7™ GMA WIRE FEEDER...

  • Page 99: Control Pc Board Removal And Replacement Procedure

    CONTROL PC 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 100 #7 and #32A. they were removed. Improper connection may lead to component damage or machine misop- 8. Disconnect meter kit wires from PC board ter- eration. minals #508 and #509. LN-7™ GMA WIRE FEEDER...
  • Page 101 Excessive force can damage the con- board. trol PC board. If the control relay does not fit, remove it and try again. 19. Reinstall the cover on the wire feeder using four hex head screws. LN-7™ GMA WIRE FEEDER...
  • Page 102 NOTES F-34 F-34 LN-7™ GMA WIRE FEEDER...

  • Page 103: Main Power Resistor (R 1 ) 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 104 3. If the wire feeder is equipped with a meter kit, remove the meter cable strap from the resistor 6. Unsolder the two wires from the resistor. mounting bolt. Remove the resistor from the wire feeder. LN-7™ GMA WIRE FEEDER...
  • Page 105 9. If the wire feeder is equipped with a meter kit, install a second washer and the meter cable strap. If a meter kit is not equipped, install only the second washer. LN-7™ GMA WIRE FEEDER...
  • Page 106 NOTES F-38 F-38 LN-7™ GMA WIRE FEEDER...

  • Page 107: Control Relay Removal And Replacement Procedure

    CONTROL RELAY 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 108 6. Reinstall the cover on the control box using four hex head screws. CAUTION 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. LN-7™ GMA WIRE FEEDER...

  • Page 109: Wire Drive Assembly And Components 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 110 On four-roll wire feeders, remove the hex head bolt, lockwashers, and flat wash- er. Remove the hex nut, lockwasher, and flat washer from the bent J-bolt. Remove the con- tact block, locator bushing, and bent J-bolt. LN-7™ GMA WIRE FEEDER...
  • Page 111 #539. Secure the motor leads to gearbox. Secure in place with two hex head the main harness using two tie wraps. screws and lockwashers. 29. Reinstall the cover on the control box using four hex head screws. LN-7™ GMA WIRE FEEDER...
  • Page 112 FIGURE F.13 – WIRE DRIVE ASSEMBLY REMOVAL (FOUR-ROLL FEEDER) MOTOR ROLL PINION GEAR MOTOR INSULATOR LOCATOR/ INSULATOR BUSHING BENT J-BOLT CONTACT GEARBOX LEAD BLOCK # 567 MOTOR MOUNTING GEARBOX SCREW COVER UPPER MOTOR INSULATOR MOUNTING SHEET SCREW LOWER INSULATOR SHEET GEARBOX MOUNTING PLATE LN-7™ GMA WIRE FEEDER...
  • Page 113 FOR TWO-ROLL WIRE FEEDERS 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 114 Remove the pivot spacer from the swing arm. 3. Pry the speed clip off of the groove pin and lift the idle roll assembly from groove pin. LN-7™ GMA WIRE FEEDER...
  • Page 115 7. Slide the pivot pin into the swing arm assembly. block. Place the flat washer and swing arm assembly on the gearbox assembly. Fasten in place with the hex head bolt. LN-7™ GMA WIRE FEEDER...
  • Page 116 NOTES F-48 F-48 LN-7™ GMA WIRE FEEDER...
  • Page 117 FOR FOUR-ROLL WIRE FEEDERS 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 118 6. Install the idle roll shaft pin and the second compartment. Ensure that the two spacers are socket head cap screw and flat washer. not lost. LN-7™ GMA WIRE FEEDER...
  • Page 119 CAUTION 9. Install the setscrew and tighten until snug. Do not use excessive force when installing the hinge pin. If hinge pin does not go in, remove it and try again. LN-7™ GMA WIRE FEEDER...
  • Page 120 NOTES F-52 F-52 LN-7™ GMA WIRE FEEDER...
  • Page 121 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 122 TROUBLESHOOTING AND REPAIR F-54 F-54 GAS SOLENOID AND CONNECTIONS REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – GAS SOLENOID DISASSEMBLY OUTLET FITTING RETAINING TUBING SOLENOID MOUNTING PLATE TUBING TUBE SLEEVE SOLENOID OUTLET FITTING SOLENOID FILTER SCREEN INLET FITTING LN-7™ GMA WIRE FEEDER...
  • Page 123 8. Remove the tubing from the gas and solenoid outlet fittings. A knife may be required to cut the tubing. 9. Mount the new solenoid to the solenoid mount- ing plate using two phillips head screws. LN-7™ GMA WIRE FEEDER...

  • Page 124: Retest After Repair

    Wire Feed Speed, LN-7™ ....... . . 50 through 500 in./min...
  • Page 125 Schematic Diagram - Control PC Board (L7209) ..........G-5 * NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered and are therefore considered to be unserviceable. Assembly drawings of these boards are no longer provided. LN-7™ GMA WIRE FEEDER...
  • Page 126 4 - 4 - 8 6 L 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. Ln-7 ™...
  • Page 127 6 - 8 - 9 0 B 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. Ln-7 ™...
  • Page 128 6 - 2 6 - 9 2 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. Ln-7 ™...
  • Page 129 SCR FIRING note: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not be totally applic- able to your machine’s specific PC board version. This diagram is intended to provide general information regarding PC board function. 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 or Technician.

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