Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; Refer to
SAFETY iii iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secouss...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TAbLE OF CONTENTS; Safety
TAbLE OF CONTENTS vi vi Page Safety .................................................................................................................................................i-iv Installation ........................................................................................................
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS; Recommended; LENGTH
INSTALLATION A-1 A-1 LN-9 GMA and LN-9F GMA Wire Feeder TECHNICAL SPECIFICATIONS INPUT POWER Supplied by power source: 115 VAC, 50/60 Hz., 350 VA WIRE FEED SPEED 80 to 980 inches per minute (2.03 to 24.9 meters per minute) VOLTAGE CONTROL RANGE 12.0 TO 60.0 VDC TEMPERATURE RANGE OPERATION: - 20 o C ...
Page 11 - MOUNTING THE WIRE FEED UNIT; MOUNTING THE CONTROL bOX
INSTALLING THE LN-9 GMA 2-ROLL AND 4-ROLL MODELS ATTACHING THE WIRE REEL STAND Both the 2-Roll and 4-Roll LN-9 GMA are shipped with-out the wire reel stand attached. The screws and wash-ers for mounting the wire reel stand are included withthe LN-9 GMA (fastened in their respective mountingholes). T...
Page 12 - ROUTING THE ELECTRODE; POWER INPUT CAbLE ASSEMbLY; FIGURE A.1 – INPUT CONTROL CAbLE AND
ROUTING THE ELECTRODE The electrode supply may be either from reels, Readi-Reels, spools, or bulk packaged drums or reels.Observe the following precautions: • The electrode must be routed to the wire feed unit so that the bends in the wire are at a minimum. Theforce required to pull the wire from th...
Page 13 - FIGURE A.2 – STRAIN RELIEF CLAMP; bOTTOM VIEW
INSTALLATION A-4 A-4 LN-9 GMA and LN-9F GMA Wire Feeder FIGURE A.2 – STRAIN RELIEF CLAMP CONNECTING THE POWER INPUT CAbLEASSEMbLY TO THE LN-9F CONTROLbOX 1. See Figure A.3. Connect the polarized plug of the K196, K595, or K596 control cable to the matingMS-type connector on the bottom of the LN-9FGM...
Page 15 - • Turn off input power to the welding; ELECTRIC SHOCK
INSTALLATION A-6 A-6 LN-9 GMA and LN-9F GMA Wire Feeder FIGURE A.4 – CONNECTION OF LN-9 GMA TO DC-250, DC-400, and CV/CVI POWER SOURCES Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at thepower source and position the switc...
Page 18 - FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES
INSTALLATION A-9 A-9 LN-9 GMA and LN-9F GMA Wire Feeder FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at thepower source and properly set the feeder polar...
Page 20 - FIGURE A.9 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES
INSTALLATION A-11 A-11 LN-9 GMA and LN-9F GMA Wire Feeder FIGURE A.9 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES N.A. Welding cable must 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 cabl...
Page 21 - MACHINE GROUNDING; TAbLE A.1 – WORK CAbLE SIzES; DIRECT WORK LEAD CONNECTION
INSTALLATION A-12 A-12 LN-9 GMA and LN-9F GMA Wire Feeder MACHINE GROUNDING LN-9 GMA wire feeders are grounded to the powersource through the input cable. The power sourcegrounding cable must be properly connected to electri-cal ground. See your power source operating manualfor details. WORK CAbLE C...
Page 22 - FOR GMA GUN CAbLES:; FIGURE A.10 – GUN CAbLE CONNECTIONS
INSTALLATION A-13 A-13 LN-9 GMA and LN-9F GMA Wire Feeder CONNECTING THE GUN CAbLE TOTHE WIRE FEEDER A variety of gun and cable assemblies are available forthe LN-9 GMA models. See the Accessories section of this manual. Lay the cable out straight. Insert the connector on thewelding conductor cable ...
Page 23 - FIGURE A.11 – SHIELDING GAS HOOKUP
HOOKING UP GMA SHIELDINGGAS CYLINDER may explode if damaged. • Gas under pressure is explosive. •· Always keep gas cylinders in an upright position and always keepthem chained to the undercarriageor a stationary support. See American National Standard Z-49.1, "Safety inWelding and Cutting," ...
Page 24 - OPERATION
b-1 b-1 LN-9 GMA and LN-9F GMA Wire Feeder OPERATING INSTRUCTIONS Read and understand this entire section of operatinginstructions operating the machine. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yoursel...
Page 25 - GENERAL DESCRIPTION
GENERAL DESCRIPTION The LN-9 GMA 2-Roll and 4-Roll semiautomatic wirefeeder models feature the precise "set and forget" dig-ital procedure control and the other welding and oper-ator features pioneered by the original LN-9 models.In addition, the LN-9 GMA models also have the fol-lowing adva...
Page 27 - CONTROLS AND SETTINGS; ELECTRODE POLARITY SWITCH:
OPERATION b-4 b-4 LN-9 GMA and LN-9F GMA Wire Feeder CONTROLS AND SETTINGS Operator controls for LN-9 GMA models are shown inFigure B.3. Controls for LN-9F models are shown inFigure B.4. Refer to these figures and the followingdescriptions of the controls. ELECTRODE POLARITY SWITCH: The polarity swi...
Page 28 - FIGURE b.3 – WIRE FEEDER CONTROLS FOR LN-9 GMA
FIGURE b.3 – WIRE FEEDER CONTROLS FOR LN-9 GMA OPERATION b-5 b-5 LN-9 GMA and LN-9F GMA Wire Feeder
Page 29 - FIGURE b.4 – WIRE FEEDER CONTROLS FOR LN-9F GMA
OPERATION b-6 b-6 LN-9 GMA and LN-9F GMA Wire Feeder FIGURE b.4 – WIRE FEEDER CONTROLS FOR LN-9F GMA
Page 30 - CIRCUIT bREAKER
OPERATION b-7 b-7 LN-9 GMA and LN-9F GMA Wire Feeder CIRCUIT bREAKER AND GROUNDING LEAD PRO-TECTOR (GLP) RESET SWITCH: These protection circuit devices are located on the front rail of the LN-9GMA model and bottom panel of the LN-9F models.See the topic "Circuit Protection and Automatic Shutdown...
Page 32 - DRIVE ROLL INSTALLATION
DRIVE ROLL INSTALLATION CHANGING DRIVE ROLLS FOR 2-ROLLWIRE FEEDERS To change drive rolls on a 2-roll wire feeder, refer to Figure B.5 and perform the following steps. NOTE: Although an LN-9 GMA model is shown in Figure B.5, the following procedure alsoapplies to LN-9F GMA models. 1. Rotate the latc...
Page 33 - GUIDE TUBE DETAIL; FIGURE b.5 – INSTALLING DRIVE ROLLS ON A 2-ROLL FEEDER
CLAMPING COLLAR DRIVEROLLHALVES SPACER(IF REQ'D) KEY OUTPUTSHAFT GUIDE TUBE DETAIL OUTGOINGGUIDE TUBEINSERT OUTGOINGGUIDE TUBE LARGERADIUS DRIVE ROLL INCOMINGGUIDETUBE SMALLRADIUS IDLEROLL CLAMPING COLLAR DRIVE ROLL HALVES SPACER(IF REQ'D) KEY OUTPUTSHAFT GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT...
Page 35 - GUIDE TUBE DETAIL; FIGURE b.6 – INSTALLING DRIVE ROLLS ON A 4-ROLL FEEDER
OPERATION b-12 b-12 LN-9 GMA and LN-9F GMA Wire Feeder CLAMPINGCOLLAR SPACER (IFREQUIRED) DRIVEROLLHALVES OUTGOINGGUIDE TUBEINSERT OUTGOINGGUIDE TUBE IDLEROLL SMALLRADIUS MIDDLEGUIDETUBE DRIVEROLL LARGERADIUS GUIDE TUBE DETAIL KEY OUTPUTSHAFT CLAMPINGCOLLAR SPACER (IFREQUIRED) DRIVE ROLL HALVES OUTG...
Page 36 - WIRE LOADING; LOWER
OPERATION b-13 b-13 LN-9 GMA and LN-9F GMA Wire Feeder WIRE LOADING Loading a 22 to 30 Lb. (10 to 14 kg) Readi-ReelPackage Using the Molded Plastic K363-PReadi-Reel Adapter: The Spindle should be located in the LOWER mounting hole. 1) Depress the Release Bar on the Retaining Collar and remove it fro...
Page 38 - CAUTION
LOADING 50 AND 60 Lb. COILS ON 1”SPINDLE (K299 or K303 Wire Reel Stand) ADJUSTAbLE WIRE REEL bRAKE The mount for standard 50 and 60 pound electrodecoils includes a two position brake assembly.Generally the brake should be a the inner position(nearest to the wire reel shaft) for wire feed speedsbelow...
Page 39 - FEEDING ELECTRODE AND bRAKE ADJUSTMENT
FEEDING ELECTRODE AND bRAKE ADJUSTMENT 1. Turn the reel until the free end of the electrode is accessible. 2. While tightly holding the electrode, cut off the bent end. Straighten the first 6 inches. 3. Cut off the first inch. Insert the free end through the incoming guide tube. 4. Insert the free e...
Page 40 - IDLE ROLL PRESSURE SETTING; PRESSURE
OPERATION b-17 b-17 LN-9 GMA and LN-9F GMA Wire Feeder IDLE ROLL PRESSURE SETTING The idle roll pressure is set at the factory backed outtwo turns from full pressure for 2-roll feeders, threeturns from full pressure for 4-roll feeders. This is anapproximate setting. For small wire sizes and alu-minu...
Page 41 - ADJUST THE POWER SOURCE; ADJUST THE LN-9 GMA CONTROLS
MAKING A TEST WELD ANDADJUSTING LN-9 GMA RESPONSEAND STARTING CHARACTERISTICS ADJUST THE POWER SOURCE DC-250, DC-400, or DC-600 1. Connect electrode lead to terminal of desired polarity. 2. Set toggle switch to same polarity as the electrode cable connection. 3. Set toggle switch to "Output Cont...
Page 42 - SELECT ACCELERATION
VOLTAGE CONTROL RESPONSE The LN-9 GMA is provided with selectable voltage con-trol response. Proper setting depends on the powersource and process being used. Refer to the appropri-ate power source connection diagram for the properconnection of the jumpers located on the LN-9 GMAVoltage Board. To ch...
Page 43 - MAKING A WELD; PROCEDURE AT END OF COIL
MAKING A WELD 1. Inch the electrode through the gun and cable and then cut the electrode within approximately 3/8" ofthe end of the contact tip for solid wire and withinapproximately 3/4" of the extension guide for coredwire. 2. Connect the work cable to the metal to be welded. The work cabl...
Page 44 - AUXILIARY EQUIPMENT CONTACTS; WIRE REEL STANDS AND MOUNTINGS; MOUNTING STAND; ACCESSORIES
AUXILIARY EQUIPMENT CONTACTS The power for 115 volt AC auxiliary equipment can beobtained from the terminals inside the LN-9 GMA con-trol box. The contacts are “hot” whenever the trigger ispressed or the unit is welding. The current draw of thiscircuit must not exceed 1/4 ampere. TURN THE INPUT POWE...
Page 45 - ATTACHING THE WIRE REEL STANDS; WIRE REEL DOOR KIT
ATTACHING THE WIRE REEL STANDS The mounting hardware for mounting the stands isincluded with the LN-9 GMA. Screws and washers areinserted in their respective mounting holes. To con-nect: 1. Remove the three 3/8 in. hex head bolts from the back of the wire feed unit. 2. Place the wire reel mounting s...
Page 47 - WIRE FEEDER ACCESSORIES; GUN AND CAbLE ASSEMbLIES; TAbLE C.1 – LN-9 GMA GUN AND CAbLE ASSEMbLIES
WIRE FEEDER ACCESSORIES bURNbACK TIMER KIT (K419) Provides a precise control of the electrode burnbackat the end of the weld. Prevents crater sticking andprovides proper stickout for starting the next weld.Recommended especially when welding with small(0.023-1/16") diameter wire at high wire fee...
Page 49 - K320 FLUX TANK LOADING
ACCESSORIES C-6 C-6 LN-9 GMA and LN-9F GMA Wire Feeder SWIVEL PLATFORM (K178-1) For all LN-9 GMA wire reel stand combinations. Formounting wire feeder-wire reel stand assembly on topof suitable Lincoln Idealarc power sources.Recommended input cable assembly length is 10 feet(3m) when using the K178-...
Page 50 - K58 MAGNETIC SEPARATOR
K58 MAGNETIC SEPARATOR The K58 is a permanent magnet type separatordesigned to fit the top of the standard fill funnel of thecontinuous flux feed system. The purpose of the separator is to remove magneticmaterials such as mill scale and any other extraneousmagnetic materials which may have been reco...
Page 52 - SAFETY PRECAUTIONS; ROUTINE MAINTENANCE; DRIVE ROLLS AND GUIDE TUbES; PERIODIC MAINTENANCE; CONTROL bOX; MAINTENANCE
SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • Turn the input supply power OFF at the disconnect switch orfuse box before working on thisequipment. • Do not touch electrically hot parts. ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUbES After ...
Page 53 - GUN AND CAbLE MAINTENANCE; FIGURE D.1 – SPEED SENSOR MODULE LOCATION
GUN AND CAbLE MAINTENANCE For instructions on periodic maintenance for the weld-ing gun and cables, refer to the manual for your specif-ic model of welding gun. PROPER SPEED SENSOR MODULEMOUNTING The LN-9 GMA Speed Sensor Module is a three leadHall-Effect switch device encased in an externallythread...
Page 54 - FIGURE D.2 – SWITCH REQUIREMENTS
The following Figures D.2 and D.3 should serve as aguide to determine if a particular gun or switch can beconnected to the LN-9 GMA and LN-9F GMA. “A” Diameter Hole to be Concentric to Wire Size .749/.747 (19.0/18.9) in. (mm) Diameter Within .008 (.20) F.I.M. 0.68-5/64 (1.7-2.0) .125 [1/8” (3.2 mm) ...
Page 55 - TROUbLESHOOTING
TROUbLESHOOTING E-1 E-1 LN-9 GMA and LN-9F GMA Wire Feeder If for any reason you do not understand the test procedures or are unable to perform the necessary tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-...
Page 56 - WIRE FEEDING PRObLEMS; TROUbLESHOOTING GUIDE
TROUbLESHOOTING E-2 E-2 LN-9 GMA and LN-9F GMA Wire Feeder PRObLEMS(SYMPTOMS) Drive rolls turn but wire will not feed,or wire feeding is rough or uneven. POSSIbLE AREAS OFMISADJUSTMENT(S) 1. Check that the gun cable is not kinked and/or twisted. Keep thecable as straight as possible.Inspect the cabl...
Page 57 - local authorized field service facility
TROUbLESHOOTING E-3 E-3 LN-9 GMA and LN-9F GMA Wire Feeder PRObLEMS(SYMPTOMS) Gun trigger will not feed wire. Digitalmeter is not lit. POSSIbLE AREAS OFMISADJUSTMENT(S) 1. Check to see if the circuit breaker is tripped. Reset thecircuit breaker. See the topic "Circuit Breaker" in the Operati...
Page 60 - WELDING PRObLEMS
TROUbLESHOOTING E-6 E-6 LN-9 GMA and LN-9F GMA Wire Feeder PRObLEMS(SYMPTOMS) Variable or "hunting" arc. POSSIbLE AREAS OFMISADJUSTMENT(S) 1. Check for worn or incorrect sized contact tip. Replace tip ifnecessary. 2. Check for worn or undersized work cables. Repair or replace ifnecessary. 3....
Page 62 - LN-9 GMA WIRING DIAGRAM; DIAGRAMS
F-1 F-1 LN-9 GMA and LN-9F GMA Wire Feeder 1- 10 -9 7G L 10 24 7 L N -9 G M A 60 1 60 2 51 0C 51 8 51 0 51 7 51 9 56 0 56 1 56 2 1 4 3 6 2 5 11 7 8 9 10 12 (J 8) (P 8) 60 1 60 2 51 0A 51 0B 51 8 51 8 51 051 7 51 9 56 0 56 1 56 2 1 2 3 4 5 6 7 8 9 10 11 12 51 8 56 2 51 8 51 0 C 2 51 7 56 1 56 0 51 9 ...
Page 63 - LN-9F GMA WIRING DIAGRAM
DIAGRAMS F-2 F-2 LN-9 GMA and LN-9F GMA Wire Feeder 1- 10 -9 7G L 10 25 0 L N -9 F G M A A B C D E 62 2 62 3 (J 4) W EL D C UR RE N T RE ED S W IT C H 62 8 52 9 C R2 W IR E FE ED M O TO R M O DU LE X1 BL AC K RE D BL UE H AL L EF FE C T IN PU T C AB LE G UN C AB LE 51 0 52 5 55 5 52 9 62 8 BL AC K R...
Page 64 - LN-9 GMA DIMENSION PRINT
DIAGRAMS F-3 F-3 LN-9 GMA and LN-9F GMA Wire Feeder LN-9 GMA DIMENSION PRINT
Page 65 - WIRE DRIVE UNIT
DIAGRAMS F-4 F-4 LN-9 GMA and LN-9F GMA Wire Feeder LN-9F GMA DIMENSION PRINT (1 OF 2) WIRE DRIVE UNIT
Page 67 - NOTES