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Lincoln Electric LN-9 User's Manual

Contents

1. ITEM DESCRIPTION PART NO 11213 4 5 6 7 8 9 1 Control Welded Assembly M13655 1 1 LN 9F Above Code 9100 1 Control Box Welded Assembly M13655 1 X LN9F amp 9FH Below Code 9100 1 Control Box Welded Assembly M13655 3 1 X LN 9F GMA 2 Resistor S10404 75 1 X 10 24 x 5 00 RHS CF000045 1 X Insulating Washer T4479 A 2 X 3 Sub Panel Assembly See P 127 S 1 X 4 Work Jack Below Code 8400 Not Shown T14280 1 X 5 Door Assembly See P 127 N 1 X 9 Circuit Breaker LN9F T12287 10 1 X 9 Circuit Breaker LNOFH amp LN9F GMA T12287 8 1 X 10 Push Button Switch T14200 1 X 11 Terminal Strip S13323 5 1 X Number Plate T10726 130 1 14 Plug Button T13597 1 1 X 17 Reed Switch Assembly S12334 26 1 X 18 Resistor T12731 34F 1 X 19 Terminal Strip T10707 1 X 22 Transformer Assembly 14651 6 o 1 23 Voltage Printed Circuit Board Assembly L6084 1 X Below Code 9000 23 Voltage Printed Circuit Board Assembly L6084 1 X Above 9000 Voltage Printed Circuit Board Insulation S16364 1 25 Warning Decal T13470 1 X 26 Patent Decal 13232 1 X 27 Start Printed Circuit Board Assembly M13750 1 X Below Code 9000 Only Not Shown 29 Potentiometer S16296 1 2 X 30 Felt Washer T14034 2 X Insulating Tube T7028 241 2 X Knob T14091 2 X 33 Warning Label S16722 3A 1 Parts Not Shown Tachomet
2. L5360 6 20 86S 6 20 86 P 107 W 2 b P 107 W 2 b Indicates a Change This Printing Q This part is obsolete and no longer available ITEM DESCRIPTION PART NO QTY 67 89 1 M12799 1 2 Power Source Lead S15017 12 1 Contactor Jumper 513472 3 2 4 Auto Equipment Lead S15017 11 1 5 Warning Decal T13470 1 6 Wraparound L4397 1 9 1 7 Nameplate M12802 1 10 Power Source Marker T10743 1 10 Rivet T8973 2 11 Auto Equipment Marker T12256 1 11 Rivet T8973 2 12 567 Contactor Early Machines L4300 35 1 L4300 35 Contactor Parts See P 28 H 12 S78 L6200 4 1 L6200 4 Contactor Parts See P 28 J 13 Relay 10834 1 1 13 Rubber Chassis Mount T10325 1 4 14 Printed Wiring Diagram 15371 1 16 Stud T6931 11 2 17 Hex Jam Nut 1 2 13 4 18 Lock Washer E106A 5 2 19 Flat Washer S9262 1 4 20 Insulating Washer S10773 9 2 21 Insulating Panel T14373 2 22 Insulating Tube T14374 2 23 Connecting Strap T8141 2 24 Flange Nut T3960 2 25 Self Tapping Screw S8025 65 2 06 12 2001 P 107 X MECHANIZED HAND TRAVEL UNIT K110 NOTE FOR PROPER LEAD CONNECTIONS SEE WIRING DIAGRAM METHOD OF MOUNTING EXTENSION
3. IU yeysoayy UOIMS peodS syoA BEA L 85n4 1523 dV 8 1 iHe 208888838 a mp ee FN TH ger ET y gt D eS 6 t 14414111111 9 gt zes Poa lt gt gt 00 924 1 299 1 iro oos 005 lt lt s 1 A ang 2 7 801 L 129 ado 9 05 Si ves pes L gt gt ozs 2 gt gt 4 zis vos doces QA 8 gt gt 525 ce M 208 dec vt gt gt sis 8 gt gt vols LNN L5 924 es 1 yw gt gt ois 6 24 93 ors eu 9 y 9 9 sco ses peng Od gt gt Si J0100uuo2 sseureu pue es 9 1 J 9 ves SIA y 121001 1 861 ENG HEC gis 018 AS 615 096 Wisi peog O d Aejep jno dosp euo peuondo ojui 10 98 UU 09 Jodunp jguondo preog o g yoegung Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni d
4. SHAR Ask 7194714 ES E ASH ge duly e EAU jua al 4 90 Janel Ab Ge Turn power off before servicing Desconectar el cable de alimentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten 0 opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas H EACRU FE e MH eol HUR phil Do not operate with pans open guards off No operar con panel ablerto o guardas quiadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de pro tection enlev s Aniage nie ohne Schutzgehduse oder Innenschutzverideldung in Betrieb setzen Mantenha se afastado das partes moventes opere com 05 paineis abertos ou guardas removidas OKRRVPAK ERVYACKEEE TERREA L EOTF EL ei Xi TM ARLES MSRM 8 euo gel HEX 42 13 JA Y Cual yb WARNING AVISO DE PRECAUCION Franch ATTENTION Germa WARNUNG Portuguese Japanese ER LEIA E COMPREENDA AS INSTR
5. ITEM DESCRIPTION PART NO QTY 1 2 3 6 71819 Mechanized Travel Power Includes K161 1 1 Case Welded Assembly M9734 1 2 Mag Amp Assembly Includes L3524 1 1 Core and Coil Assembly M9017 1 XIX Resistor S10404 15 1 Insulation T11134 1 1 XIX Terminal Strip T10707 1 XIX Condenser T11577 37 1 XIX Rectifier Assembly S13707 1 5 Terminal Strip S8542 1 XIX 6 Number Plate T10726 60 1 7 Relay S22182 1 8 Lead Grommet T9274 1 1 XI 8 Lead Grommet T9274 2 1 X 9 Adapter Box Assembly Includes M11617 1 Amphenol Connector Next to Toggle Switch S12021 3 1 XIX Toggle Switch T13083 1 XIX Amphenol Connector Opposite Side of Box from Switch S12020 6 1 XIX 10 Connector T9639 2 1 XIX 13 Fuse 1 8 Amp T10728 9 2 XIX 14 Fuse Holder S10433 2 16 Nameplate M9730 1 18 Front Panel S11344 1 23 Fuse Identification Sticker T12607 9 1 24 Insulation T11472 5 1 XIX 25 Spacer S10040 33 1 XIX 26 Hex Head Screw 1 4 20x3 00 1 27 10040 34 1 28 Wiring Diagram S13868 1 XI 28 Wiring Diagram M20116 1 X 30 Relay 15122 10 1 IX 33 Fuse T10728 10 2 X X 34 Fuse Identification Sticker T12607 10 1 Specify Cable Length 05 10 2005 P 107 W 2 a P 107 W 2 a CONTACTOR KIT K240
6. Sec N2 2 sad men FN GY YY A OO Sec N2 2 0 Wire Feed Rolls and Guide Tubes Two Roll Wire Drive System esse Sec 2 2 1 Setting Drive Roll Spring Pressure Two Roll Wire Drive System Sec N222 Wire Feed Rolls and Guide Tubes 4 Roll Wire Drive System reines Sec N2 2 3 Setting Drive Roll Spring Pressure 4 Roll Wire Drive System Sec N 2 2 4 Wire Feed Unit and Wire Reel Mount Models N and S uu AAA UU Sec N 2 2 5 Input Cable Connections to LN 9 and 9H cscccesssssssssssssssesessesesssscssecsusscansseevsessavsrsaracsessvassesvsteatavensavacsecss Sec N2 2 6 1 Models N or S 2 Models NE or SE Flux Tank Installation Models S and SE u AAA LILI III A LL AU Sec N2 2 7 Installation of the LN 9F and Sec N2 2 8 1 Wire Feed Mechanism 2 Control Box 3 Electrical Connections Wire Feed to Control Box 4 Input Cable Connections to LN 9F and 9FH Control Box 5 Electrode Routing G n and Gun Cable 2 trece GO edP E RW WU Sec N2 2 9 Electrical Installation iu ien Gu mae meon E een d habs etie eere Sec N2 3 Input Cable Connections to Power Source inner Sec N23 1 Equipment Components Sec N2 3 2 Connection Diagrams tcr bete ce TO p IIR YT b b Rp odi Sec N2 3 3 1 Wire Feeder to Lincoln Power Sources 2 K317 and K318 D
7. NOTES LN9 AND LN9 GMA LINCOLN P P 127 U P 127 U K318 DUAL PROCESS CONTACTOR KIT 21 L6224 10 8 82G LN9 AND LN9 GMA 1 96 LINCOLN go P 127 U 1 P 127 U 1 Indicates a Change This Printing For Code 8002 use parts marked X in Column 1 For all other Codes use parts marked X in Column 2 Q This part is obsolete and no longer available LINCOLN P ITEM DESCRIPTION PART NO QTY 1 2 678 9 1 Case M13673 1 o 1 1 Case M13673 2 1 2 Wraparound L3153 1 3 Contactor Less NVR Coil L4300 31A 1 3 Contactor Less NVR Coil L4300 33A 1 NVR Coil S17 3 1 4 Contactor Less NVR Coil L4300 30A 1 4 Contactor Less NVR Coil L6200 32A 1 NVR Coil S17 3 1 5 Contactor Jumper M8427 1 1 6 Relay S14293 7 1 6 Rela S14293 8 2 8 Relay S14293 7 1 8 Rela S14293 7 2 9 Lead Clamp T12563 11 2 11 Terminal Strip S8542 1 2 11 Terminal Sirip S8542 2 9 2 Number Plate T10726
8. Door Assembly LN9F Only Includes L6185 1 1 Door Assembly LN9FH Only Includes L6185 2 Door Assembly LN9F Metric Includes L6667 1 1 Door Assembly LN9FH Metric Includes L6667 2 1 Door Assembly LN9F Metric Includes L7091 1 Door Assembly LN9FH Includes L7091 2 Door Assembly LN9F GMA Includes L7367 1 1 Door 516336 0 1 X X 1 Door S16336 2 X 1 Door 516336 1 1 2 Button Plug T13597 2 2 Button Plug T13597 2 4 X 3 Nameplate 16005 1 3 Nameplate LN9F Only L6183 o T SX ENS 3 Nameplate LN9FH Only L6184 o 1 3 Nameplate Metric L6183 1 3 LN9F GMA L7348 3 Nameplate LN9FH Metric L6184 1 1 4 Meter amp Board Assembly M13650 1 4 Meter amp P C Board LN9F Only L6181 1 XJ 4 Meter amp P C Board LN9FH Only L6181 1 4 Meter amp P C LN9F Metric L6687 4 Meter amp P C Board LN9FH Metric amp GMA L6688 5 Switch Polarity T13111 1 6 Switch 8 Transient Protector Assembly T14535 6 Switch Direction T10800 7 1 1 7 Bezel Assembly S17414 1 ele XIX 8 Meter Shield Std Clear Lens T14771 1 8 Filter Lens T14807 1 9 Meter Shield Frame M13572 1 13 Lock Tab T10045 40 1
9. Wire feeder 71 control cable To work To A wire feeder To B wire feeder M14549 1 20 89B 91Oc Assembly and Installation N A Place mode switch on power source to CV Innershield and place each mode switch on dual process control in the position reguired by process used with wire feeder Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Connection shown for positive polarity for negative polarity reverse electrode and work cables connected to power source output studs For DC 600 codes below 8200 1 When using two LN 9 wire feeders connect jumper on the power source terminal strip as shown between terminal and P 2 When using LN 8 wire feeders tape up control cable leads and Connect jumper to power source terminals and 5 There is no N P S terminal strip on codes above 8200 Tape up leads P and N Connect the control cable ground lead to the frame terminal marked 747 near the power source terminal strip The power source must be properly grounded Use 14 or larger wire physically suitable for the installation and connect it directly to the work piece keeping it separate from the welding work lead circuit and connection Bolt and tape connection N B N C N D N E N F N G N A Mode switches on dual process kit are not functional when connected to power source W
10. Position sion gt pt Stickout Extension Rear Wheel Assembly 9715 8 Wheel Assembly 3 10888 16 Guide Roll Asbly T 6675 2 _ Insulating Tube 90781 Wing Screw 2 S 10773 35 Insulating Washer 4 S 9262 22 Flat Washer 2 E 106 A 1 Lockwasher ____ 2 10 24 x 7 8 Round Head Screw 2 T 2078 3 Wing Screw 1 Guide Roll Holder T1688 Short Guide Roll Arm 1 i 11688 1 Adapter Ring o a 17 15 11865 Sec N4 4 16 PROCEDURE AT END OF COIL When the wire on the reel is used up the following procedure is to be followed for removing the old wire from the conductor cable and loading a new reel 1 Cut the end of the electrode off at the gun end Do not break it off by hand since this puts a slight bend in the wire and makes it difficult or impossible to pull it back through the nozzle 2 Uncouple the gun conductor cable from the LN 9 3 Lay the cable out straight 4 Using pliers to grip the wire pull it out of the cable from the connector end Do not pull it from the gun end 5 Put the conductor cable back on the wire drive unit after the electrode has been removed 6 Load a new reel of wire and feed it through the cable as described in the section on Loading Machine with Electrode March 1979 96Au Replace item 15 with item 16
11. WHATTODO gt Keep as straight as possible Inspect cable and replace if necessary Remove wire from gun and cable feed new wire Note any obstruction Replace gun and cable if necessary A Drive rolls turn but wire will not feed or wire feeding is rough or uneven Gun cable kinked and or twisted Wire jammed in gun and cable 910c Incorrect drive rolls and guide tubes incorrect drive roll assembly or pressure setting Gun cable dirty Worn drive rolls Electrode rusty and or dirty Worn nozzle liner Partially flashed or melted contact tip Be sure the wire diameter being used is stamped on drive rolls and guide tubes Replace if necessary Check proper assembly and pressure setting Clean per Sec N6 2 3 instructions Replace on reverse split drive roll type Replace the electrode if it is rusty If conditions are extremely dirty or electrode is old solid wire only put a wiper on the wire before it enters the guide tube Use a piece of cloth or felt saturated with Pyroil held around the wire with a light clamp Replace nozzle liner Replace the contact tip Maintenance Sec N6 6 continued TROUBLE B Variable or hunting arc Gun trigger will not feed wire Digital meter is not lit Gun trigger will not feed wire Meter is on but only reads zeros in both the Volts and Wire Speed settings of the meter switch Gun
12. 14 Dial Plate S16277 1 15 Security Panel S16275 1 JXTXTXTX 17 Switch LN9F Only T13111 1 17 Switch LN9FH Only T13381 2 1 IX 17 Switch LN9FH Metric LN9F GMA Includes S16670 5 1 Knob T13639 18 Switch T10800 4 1 18 Switch Hot Cold Interlock T10800 12 1 19 Switch 4 Actuator Assembly T14751 1 1 20 Meter amp Pin Assembly S16636 1 20 Digital Meter P C Board M14490 21 14537 1 22 Printed Circuit Board Insulation T14468 1 X Items Not Shown Fiber Washer S10773 15 2 IX X XIX Felt Washer T14034 2 Insulating Tube T7028 241 2 IX X XIX Potentiometer S16296 1 2 IX X XIX Knob T14091 2 XIX X X LN9 AND LN9 GMA 10 04 2005 LINCOLN 5 Q This part is obsolete and no longer available P 127 P P 127 P K317 DUAL PROCESS KIT D gt O M 16Y17 5 LN 14 Y15 ot 13 ram EN 12 a e e M13524 10 8 82G LN9 AND LN9 GMA LINCOLN amp 1 96 P 127 P 1 P 127 P 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO GTY 1 2 6789 1 Mount
13. Date Purchased Where Purchased Whenever you reguest replacement parts or information on this eguipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this eguipment Save this manual and keep it handy for guick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment The Lincoln Electric Company Index Cleveland Ohio 44117 1199 SEC N1 INDEX Sec N2 Installation Mechanical Installation
14. Larger wire settings are accurate for most all applications Some unusual circumstances will reguire fine tuning For Aluminum Wire Each set of rolls should have their pressure set independent of the other To do this release and open the other guick release arm while making each adjustment Follow the procedure below for each adjustment a With low idle roll pressure load the feeder so it s ready for welding b Run the feeder at a slow speed about 100 IPM and reduce the idle roll pressure until the idle roll stops rotating c Slowly increase idle roll pressure until the idle roll just starts to rotate consistently with the drive roll with stoppage then add an extra 1 4 to 1 3 tum more idle roll pressure This pressure setting should be optimum for feeding and to avoid bird nesting by allowing the drive roll to slip on the wire if a gun cable jam or stoppage occurs If using harder or larger diameter aluminum wires more idle roll pressure if necessary can be tolerated However if the pressure reguired to properly feed the aluminum wire also permits bird nesting or excessive slippage results in aluminum pickup in the drive roll groove the loading on the wire by the gun cable or wire reel should be inspected and alleviated October 1991 Sec N2 2 5 WIRE FEED UNIT AND WIRE REEL MOUNT Models LN 9N LN 9HN Obsolete and LN 9S 1 The wire feed unit and wire reel mount are shipped separately To
15. Brush Cap Stature Electric M13312 13 2 X 120 Brush Cap Universal Electric M9655 7B 9 2 X 12E Brush amp Spring Assembly Stature Electric M13312 12 2 X 12E Brush amp Spring Assembly Universal Electric M12254 1F 2 X 12F Insulating Bushing T14058 1 3 X 12G Plain Washer S9262 147 3 X 12H Lock Washer T4291 A 3 X 12J 8 32x1 125 Round Head Screw CF000007 3 X 12K Motor Insulator M13479 1 1 X 12L Insulation Not Shown T13911 1 X 12M Speed Clip Not Shown T10982 5 1 X 13 Gearbox G2232 1 14A Swing Arm M16373 2 X 14B Swing Arm Pin S19828 1 X 14C Set Screw S11604 6 1 X 14D Quick Release Pin 19829 2 X 14E Pivot Block Shaft S19827 2 X 14F Pivot Block S19826 2 X 14G Roll Pin T9967 27 2 x 14H Swing Arm L8364 1 X 15A Cam Not Shown 19824 4 X 15B Roll Pin Not Shown T9967 5 4 IX 16 Screw amp Handle Assembly T13858 1 LN9 AND LN9 GMA 01 01 2007 Q This part is obsolete and no longer available LINCOLN ELECTRIC P 127 L 2 P 127 L 2 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 1 67819 17A Conductor Block S19830 1 17B 1 4 20x1 50 Hex Head Cap Screw CF000141 1 X 17C Plain Washer S9262 23 2 X 17D Lock Washer E106A 2 2 X 17E Stud T9781 129 1 17F Insulating Tube T7028 13 1 17G Insulating Washer S10773 53 1 X 17H 1 4 2
16. H ade Nid OL 3123NNOO 0344145 r 028 38 O H3dWRF 2 4 TOHINOO Mes nes us i 48 Nid OL Q3123NNOO O3ddlHS 9 38 i Ms i OL 3178 2 4 JOVLIOA i lt 8 Nid OL G3dd HSpg 38 OL H3dWnr 2 d 3OVLTOA i es i GHYOB 94 L LE h t ne L SS HOLMS o 3907831NFQ 102 LOH HOLIMS i 13538 gu 359 T ou AS HOLMS Y naa NOLLO3810 L gozo HOLMS sinq 83134 a DT AMY Od 7 e an as AN p di gt bess 3sna 88 QUYOB o d AVI3Q 1594 rftt rr 100 4040 HOLOYINOO TYNOLIdO OLNI 399114 St UOLO3NNOO SS3NUVH g 9 o i sp 53 i 109 1 uM ro 4 ONY G3AOW3E Si HOLO3NNOO H3dWnP 1YLSO3HH 129 1061600 YNOLLdO 24 veo 99 1 H a sto i t 8 1g gt sto i rit us 1 1 Re 26 els LY rope i s SEMY 92 8015 TE Es 559 jE ro 8 3 959 Fee 222 Od 3 L gt l ceo be pos Sem 45 1 H V 15 113034 1 2 92 09 YO BUA 5 1041400 03345 J IXXIIXX Du TILLITI Nid 1Y1SO3HH 101409 291221 L van vio Hols DIN mc HOLIMS 80193738
17. M13704 M13914 M14550 M13917 M13915 M13913 M15082 M14550 Connect the dual process contactor kit control cable to the power source per the connection diagram Two 3 0 leads are provided to connect the power source output studs to the kit for opposite polarity operation Only one lead is used for same polarity operation Connect work lead and wire feeder electrode leads as shown on the diagram Put cover back on control box and unit is ready to operate CAUTION When fixture mounted wire feeders are used the wire reels must be insulated from each other and insulated from their mounting structure ELECTRODE FECOER ELECTRODE AND CONTROL CABLE AND CONTROL CABLE D CONNECT A WIRE CONNECT 8 WIRE 0 THIS SIDE 10 THIS SIDE MODE SWITCHES o CY SUBMERGED ARC Sm CY TRNERSHIELD OWE SOURCE MODE SWIICH MUST B dg BE IN CY IMNERSHIELD POSITION SAME POLARITY ON F EDERS CONNECT POWER SOURCE OUTPUT STUD OF REQUIRED POLARITY TO OUTPUT STUD ON BACK OF THIS BOX AND CONNECT THE OTHER POWER SOURCE OUTPUT Stun WORK TRANSFER SWITCH TO BE UN UP POSITION OPPOSITE POLARITY ON PERDERE CONNECT NEGATIVE POWER SOURCE OUTPUT MUD 10 A 3100 AND CONNECT Positive POWER SOURCE OUTPUT 10 8 STUP CONNECT WORK CABLE OUTPUT 1108 ON BACK OF THIS BON TRANSFER SWITCH TO RUIN DOWN POSITION DUAL PROCESS CONTACT
18. P 107 X L3865 4 3 81E Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO 1234567 89 1 Gun Drive Unit Assembly Includes K110 1 1 Mounting Clamp M9108 1 2 Thumb Screw T9078 3 1 3 Control Cable and Plug S11837 1 5 Grommet T9274 1 2 6 Truss Head Screw 8 32x5 8 2 7 Insulator Bushing T11215 2 2 8 Drive Wheel M9122 1 9 Hollow Set Screw Cup Point S11604 13 1 11 Resistor T12731 3 1 14 Reversing Switch T13111 1 15 Insulating Plate T11221 1 16 Control Box Back M9027 1 1 17 Control Box Front M9693 1 19 Dial Plate S11163 1 20 Knob T11157 1 21 Insulation T11228 1 22 Rheostat T10812 9 1 23 Gear Box assembly See P 107 Y 1 26 Motor S11162 1 27 Adapter Plate M9109 1 28 Mounting Clamp Extension M9142 1 05 10 2005 P 107 Y GEAR BOX FOR K110 OTT OT P 107 Y Use only the parts marked X in the column under the heading number called for in the model index page Indicates a Change This Printing ITEM DESCRIPTION PART NO GTY 819 Gun Drive Gear Case Assembly Includes L3569 1 1 Gear Box L3568 1 2 Needle Bearing S10116 2 3 3 Retaining Ring S9776 9 3 4 Vertical Shaft Assembly S11160 1 5 Cross Shaft Assembly S11161 1
19. P 127 L P 127 L WIRE DRIVE MOTOR amp GEAR BOX ASSEMBLY LN9 amp LN9F 4 Roll Drive 1 17 97 LN9 AND LN9 GMA LINCOLN P P 127 L 1 P 127 L 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO GTY 1 2 67819 Wire Drive and Gear Box Assembly G2223 1 LNOF 4 Roll includes Wire Drive and Gear Box Assembly G2223 4 LN9 4 Roll includes 1A 6 32x 375 Round Head Screw CF000003 2 X 1B Lock Washer E106A 13 2 X 2 Cover Assembly T14326 1 3A 6 32x 375 Phillips Round Head Screw CF000108 1 X 3B Lock Washer E106A 13 1 X 3C Cap T14246 1 X 4A 8 32x 375 Round Head Screw CF000006 2 X 4B Lock Washer T4291 A 2 X 4C Plain Washer Not Shown S9262 3 2 X 5 Plain Washer Shim S16268 1 4 6 Slotted Disc S16180 1 X 7 Tachometer Pick Up P C Board M14700 1 8 Pick Up Housing Assembly M13578 1 9 Insulator S20425 1 X 10 Heat Sink M13579 1 X 11A 8 32x 375 Round Head Screw CF000006 2 X 11B Lock Washer T4291 A 2 X 12A Drive Motor Assembly LN9 4 Roll includes L5974 8 1 X Drive Motor Pinion amp Shaft includes LN9 4 Roll S16470 1 1 X 12A Drive Motor Assembly LN9F 4 Roll includes L5974 2 1 X Drive Motor Pinion amp Shaft includes LN9F 4 Roll S16470 2 1 X 12B Pinion S15013 4 1 X 12C Roll Pin Gear to Shaft T9967 33 1 X 12D
20. Plug Button T13597 2 4 LN9 AND LN9 GMA 01 01 2007 Q This part is obsolete and no longer available LINCOLN P P 127 E P 127 E BASE PLATFORM LN9 amp LN9 GMA 2 Roll amp 4 Roll we eu PRE 712 of 13B LN9 AND LN9 GMA LINCOLN P 1 28 2002 P 127 E 1 P 127 E 1 Indicates a Change This Printing Use Column one for 2 Roll Use Column two for 4 Roll ITEM DESCRIPTION PART NO 11213 14 5 6 7 8 9 1 Base Assembly Below Code 8000 L5778 4 1 1 Base Assembly Code 8178 thru 8180 L5778 5 1 1 Base Assembly Code 8420 and up and L5778 7 1 LN 9 amp LN 9H Only 1 Base Assembly LN9 GMA Only L7269 1 1 Base Assembly LN9 4 Roll Only L8815 1 1X 2 Circuit Breaker LN9 2 amp 4 Roll Drive T12287 10 1 2 Circuit Breaker LN9H LN9 GMA 2 amp 4 Roll Drive T12287 8 1 Above Code 8000 3 Push Button Switch GLP T14200 1 4 Hot Cold Interlock Switch Above Code 8000 T10800 12 1 5 Input Connector S12021 12 1 6 Output Connector Assembly S12021 3 1 7A Transformer Assembly S14651 5 1 7B Sems Screw T10082 27 2 7C 8 32 Hex Nut CF000042 2 8 Self Tapping Screw S8025 73 8 9A Resistor S10404 75 1 9B 10 24x5 00 Round Head Screw CF000045 1 9C Insul
21. RETURN TO MAIN MENU IM294 C LN 9 SEMIAUTOMATIC WIRE FEEDER For Submerged Arc Innershield amp and Other Open Arc Semiautomatic Arc Welding Processes For Operation with Appropriate Lincoln Safety Depends on You Lincoln arc welding and cutting eguipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EGUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL 150 9001 ime j Ed as A Se ra ISO 9001 Ri CERTIFICATE NUMBER 30273 Power Sources LINCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 1 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For G
22. 1G Ring Magnet Not Shown S18011 1 X 2 Motor Insulator Spacer M16803 1 X 3A Bushing T14058 1 3 IX 3B Plain Washer S9262 147 3 X 3C Lock Washer T4291 A 3 X 3D 8 32 x 1 50 RHS CF000119 3 X 5 Thumb Screw S19924 3 X 6 Set Screw S11604 6 1 X 7A Sems Screw T10082 26 2 X 7B Collar Assembly Below Code 10300 T12341 2 X 7B Collar Assembly Above Code 10300 S21193 2 x 7 Key Below Code 10300 M8776 82 2 X 8 Hall Effect Switch LN9 GMA S18160 1 1 X 8 Hall Effect Switch LN9F GMA S18160 1 1 X 9A 10 24 x 1 00 RHS CF000038 1 X 9B Lock Washer E106A 1 1 X 9 Plain Washer S9262 27 1 X 10 Locator Bushing T14031 1 X 11 Bent Bolt S20629 1 1 X 12A Hex Head Screw 1 4 20x1 750 2 X 12B Lock Washer E106A 2 2 X 12C Plain Washer S9262 23 2 X 12D 1 4 20 Hex Nut CF000017 1 X 13 Conductor Block M13972 2 1 X 14 Molded Hand Screw T13858 1 X 15 Sems Screw T10082 4 1 X 16A Reed Switch Assembly LN9F GMA 4 Roll 12334 47 1 X 16A Reed Switch Assembly LN9 GMA 4 Roll 12334 43 1 X 16B Reed Switch Energizer M15173 1 X 17 1 2 18 x 750 HHCS CF000029 1 X 18A 1 2 13 x 1 75 HHCS CF000277 1 X 18B Lock Washer T9695 8 1 X 18C Plain Washer LN9 GMA S9262 1 1 X 18C Plain Washer LN9F GMA S9262 125 1 X 18D 1 2 13 HJN CF000054 2 X 19 Gear Box Insulation Lower T11472 26 1 X Not used on LN9 GMA 4 Roll O This part is obsolete and
23. 21 lead between the input amphenol connector of the LN 9 and its polarity switch refer to the LN 9 wiring diagram This in line connection consists of a red insulated male and female 250 x 032 terminal pair located in the lead harness running up along the right side of the wire feed motor inside the control section of the LN 9 and LN 9H obsolete models and in the lead harness at the inside lower left corner of the control box near the input amphenol of the LN 9F and LN 9FH obsolete models If desired by opening this 21 lead Operating Instructions Sec N4 4 4 continued connection a user provided direct work lead eguipped with 250 x 032 female guick connect terminal can be connected to the male side of the 21 lead splice This direct work lead connection must be tape insulated strain relieved and routed outside the LN 9 control box and connected directly to the work With the use of either direct work lead connection method the LN 9 regulates the output of the power source to hold the arc voltage constant even with voltage drop changes of the electrode lead work lead or work lead connection Should the direct work lead be disconnected from the work the LN 9 wire feeder will stop welding shortly after the arc is struck See Item F in Troubleshooting Section N6 April 1987 Sec N4 4 5a TRIGGER INTERLOCK SWITCH Below Code 7981 With the Trigger Interlock switch off the wire feed motor
24. 7 64 amp 2 8 Hardfacing KP502 7 64H KP2123 4 T12057 7 64H S12722 7 64H KP2119 1 KP2120 1 1 16 amp 1 6mm KP503 1 16A KP2123 3 S17729 1 16 S17731 16 KP2117 3 KP2118 3 3 64 amp 1 2mm KP503 3 64A KP2123 2 S17729 3 64 S17731 3 64 KP2117 2 KP2118 2 035 amp 0 9mm KP503 035A KP2123 1 S17729 035 S17731 035 KP2117 1 KP2118 1 Some Drive Rolls Available Only in a Kit LN9 AND LN9 GMA 01 01 2007 LINCOLN NOTES LN 9 AND LN 9 GMA LINCOLN 5 P 125 N P 125 N STAND ASSEMBLY FOR READI REEL K377 CURRENT MOLDED OBSOLETE ALUMINUM PLASTIC SPINDLE ASSEMBLY 14 WIRE WHEEL L SUPPORT WIRE WHEEL SUPPORT OBSOLETE MOLDED PLASTIC SPINDLE ASSEMBLY 5 LEZ WIRE WHEEL SUPPORT L6940 12 19 85G 11 25 97 P 125 N 1 P 125 N 1 Indicates a Change This Printing For Obsolete Molded Plastic Spindle Assembly Use Column 1 For Obsolete Aluminum Spindle Assembly Use Column 2 For Current Molded Plastic Assembly Use Column 3 ITEM DESCRIPTION PART NO QTY 1234567 89 1 Wire Reel Support Assembly L6
25. 8 and LN 9 type wire feeders April 1987 Sec N3 3 16 K303 WIRE REEL ASSEMBLY Includes the same frame as used in the K376 It also has a shroud that covers the wire reel April 1987 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N3 3 17 K304 WIRE REEL ASSEMBLY A reel and brake assembly in a closed housing with a hand crank for extension loading 50 and 60 lb coils can be used and it is easily attached to the LN 7 LN 8 and LN 9 type feeders April 1987 Sec N3 3 18 K377 WIRE REEL ASSEMBLY A small mounting stand for Readi Reel coils or 10 30 pound spools with 2 I D This assembly includes a small frame which is attached to a wire spindle similar to the K162 H spindle A K363 P Readi Reel is supplied for Lincoln Readi Reel Electrode Coils Without the adapter the unit can handle spools with a 2 LD 12 max O D and 4 06 max width The spindle has an adjustable braking system Holes for attaching unit to LN 7 LN 8 and LN 9 s are provided April 1987 Sec N3 3 19 Mas K378 WIRE REEL ASSEMBLY A small mounting stand for 13 14 pound Innershield coils This assembly includes the same smaller frame as used in the K377 and a fully enclosed canister system This System has a fixed brake for the 14 pound coil April 1987 910c Assembly and Installation Sec N3 3 20 K305 LN 9S WIRE REEL AND FLUX TANK ASSEMBLY Includes a reel and brake assembly in an open shroud wit
26. At the end of the weld release the trigger and lift gun from the work after the arc goes out October 1991 Sec N4 4 15 File as Sec K3 2 3 in IM 274 MAKING SUBMERGED ARC WELDS Gun Operating Positions K114 Sguirtgun The K114 Squirtgun is used either with or without the mechanized hand travel unit K110 With the LN 6 LN 8 and LN 9 a K161 Mechanized Travel Power Pack must be installed when using the K110 Since the travel unit assures uniform travel at the maximum usable speed and reduces the tendency to waver off the seam it is recommended for most applications The following photographs show suggested gun positions to produce the best welds in the least time For proper flux feeding these same positions should be maintained when the gun is hand held and the mechanized travel is not used Figure 1 and Figure 2 Travel Unit Adjusting Loosen the motor mounting wing nut to adjust the travel unit Figure 1 Move the travel unit up and down or around the gun nozzle to suit different welding applications Figure 2 Pull the motor controlled plug out to remove the travel unit from the gun Flux Depth The depth of the flux pile is controlled by the gun height Gun height is measured from the lower tip of the nozzle flux cone to the plate Proper gun height is the height at which a minimum of flux is used without excessive arcing As a general rule the required gun height increases as the travel speed decreases and the vol
27. Connect the control cable ground lead to the frame terminal marked 77 polarity switch on power near the power source terminal strip or to an unpainted frame screw The Source power source must be properly grounded N B B Extend lead 21A and 21B using 14 or larger insulated wire physically suitable for the installation An 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience these extended 21A and 21B leads should be taped to the welding work lead Each lead must be connected directly to the M13915 Work and leads must not be connected together 11 2 79 Sec N2 3 3 S K318 DUAL PROCESS CONTACTOR KIT R3S AND SAM CONNECTION TO TWO LN 8 s OR TWO LN 9 s FOR OPPOSITE POLARITY OPERATION For 50 Hz Operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B Welding lead contacter Kt N A Welding cables must be of py proper capacity for the current and duty cycle of immediate and future applications re Bolt and tape connections Welder control cable 21A 21B To work Pawer source N B N C Tape up leads N D Put transfer switch in opposite N E letal n power source terminat stip polarity on feeders position E Mode switch has no effect B when us
28. Gear Box Assembly 4 Roll Drive P 127 J Wire Drive Motor amp Gear Box Assembly 2 Roll Drive P 127 K Re RS NF YR NT E Le P 127 B 1 Conversion Kit CHER RT nb rene des I Pa aw Verde ER A CA ER dr P 127 T amp V LN 9F GMA Wire Drive Motor amp Gear Box Assembly 4 Roll Drive P 127 J Wire Drive Motor amp Gear Box Assembly 2 Roll Drive P 127 K COMMON BOX oa vos rary Ud P 127 M Door ABSEmDIV sat ahh y Y Dw Y Et GL A Y o P 127 N Instrument cu YG a Ad dn UN MR YA AE AFAN P 127 S Meter PatielASSBITIDIV us wn eau tok wdd e de S Re ET DANA maar P 127 G Op IG IS EC RE GA Yd Y FR ER P 127 B 1 Conversi n Kit Cham oea rnc P 127 T V LN 9 AND LN 9 GMA LINCOLN H 10 15 96 P 127 B 1 OPTIONAL EQUIPMENT LISTING Miscellaneous Options Available for your machine are listed below LN 9 Squirt Welder Options Standard Options P 127 B 1 Input Cable K196 and Extension LN9NE Cable Assemblies P 107 M 50 and 60 Wire Support eu e P 107 O Wire Reel Shaft 1 00 P 107 P Crank Assembly pua to RACER cocoa racine P 107 R Flux
29. Motor Gear Box Assembly 2Roll Drive P 127 H Wire Drive Motor amp Gear Box Assembly 4Roll Drive P 127 L Olei tlele EAEE EE e ete dra P 127 B 1 Conversion KIDOBarts os cross e uta Se EUER C Re A OR P 127 T amp V LN 9 Wire Feeders LN9F FH cos cos m vat ete beet uf A ir p CE ER Eo Zee d ER P 127 G Wire Drive Motor amp Gear Box Assembly 2 Roll Drive P 127 H Wire Drive Motor amp Gear Box Assembly 4 Roll Drive P 127 L CODO BOX Msc P 127 M Door Assembly pe RYN eiat eredi p dese equ due J oes P 127 N le mel cad ed et RE DC pc ve e SR ere ren ts aic se tpa tei P 127 S sup Wr fe yh dyed wenn Re aug I RY NY A AN P 127 B 1 Conversion Kit CHE Sep wre ae each DATA ee YN Y Abad da e da 127 amp V LN 9GMA Control Box 2 Roll amp 4 Roll Drive P127 C Hinged Door Assembly 2 Roll amp 4 Roll P127 D Base Platform 2 Roll 8 4 Roll P 127 E Control Panel Instrument Assembly Roll amp 4 Roll Drive P 127 F Meter Panel Assembly aea CW AS RYW Rar oe E COR P 127 G Wire Drive Motor amp
30. Wash all the material out of the aluminum tube Clean out the short pinched section this should have a gap of between 005 050 to allow a small amount of air to escape when the eguipment is being used If this end piece is badly corroded replace it with a new end piece Loosen the collar on the 2 1 8 inch steel filter tube and take the filter tube off the machine Wash out completely Fit steel tube back into its bracket and attach the aluminum tube to its bottom Fill steel tube to within two inches of the top with any clean Lincoln submerged arc welding flux Raise the steel tube into place and tighten the collar When the air pressure is turned on again part of the flux in the steel tube will be forced into the coiled tube Be certain a small amount of air is escaping from the pinched end of the copper tube March 1979 Maintenance Sec N5 5 6e HAND TRAVEL UNIT K110 Check the lubrication in the gear box every three months If the motor worm and its worm gear appear dry wipe a thin coating of a good non fluid grease eguivalent to Clark Oil Co Sea Gull Speed Reducer Lubricant on each Do not add too much or the motor will be overloaded Lubrication for this first reduction must be by spatter and drip not by running in a pool of grease Once each year flush out the gear box and relubricate To do this remove both the output shaft assembly and the motor assembly Flush the box with a good solvent Force fresh grease in th
31. be removed from the handle To reassemble the unit follow this procedure in reverse When finished with the reassembly make certain that the electrical connection locking screw item 33 is loosened before assembling the gun and then retightened before attempting to weld Maintenance Sec N6 2 3 GUN CABLE CLEANING A dirty gun cable can cause rough and erratic wire feeding Therefore the cable liner must be cleaned periodically Procedures differ depending upon whether the cable has a permanent core or removable liner 1 Permanent Core Cables K112 500 K113 K114 and Obsolete K133 Remove the cable from the wire feeder Lay it out straight on the floor Remove the contact nozzle tip from the gun Using an air hose and only partial pressure gently blow out the cable from the gun end Too much pressure at the start will cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out 2 Cable with Removable Liner Obsolete K112 To clean the liner first disconnect the cable from the wire feeder and remove the gun nozzle from the gun handle To remove the liner from the cable insert a 3 16 diameter rod about 18 long into the gun end Push the liner out of the cable far enough that it can be pulled from the opposite end If the liner does not pull out easily do not force it Continue to push the liner until it pulls freely To
32. below 3 Fasten dual procedure control box to the rheostat panel with two 10 mounting screws supplied 910c Dual Procedure Control Box 10 Mounting Screw Rheostat Connection Receptacle Rheostat Connection Plug LN 9 Control Box Door shown in open position and 10 Mounting box mounted in Screw place 4 Remove rheostat connection plug from its receptacle and plug into dual procedure receptacle which is accessible through a hole in the LN 9 rheostat panel 5 Close door and replace screws 6 Fasten security panel and latch that was removed from LN 9 to dual procedure control box as shown below 7 The selector switch can be mounted on either side of the gun handle The unit is shipped for mounting on the left side of the gun and is best suited for operating gun with the right hand If required to mount switch on the right side of the gun first remove the mounting plate from the switch housing and reassemble the mounting plate to the back side of the switch housing To mount the unit on the gun remove the two trigger mounting screws from side of gun trigger and fasten the selector switch to gun as shown below Use one of the standard screws and the 8 32 x 3 4 long screw provided as shown on the next page Security Panel Dual Procedure Mounting Control Box Screws Latch and Mounting Screw Gun Trigger Selector Switch Control cable Control Cable Assembly and Installation Sec
33. ed me N A Welding cables must be of proper capacity for the current SAF 600 SA 800 Electrode polarity switches on power source and or field controi must be set on positive polanty rower Copel bau esl adii iia and duty cycle of immediate m ful 2913275767 GE ad and s applications t N B Bolt and tape connections N C Tape up leads N D Put transfer switch in same polarity on feeders position i N E Mode switch has no effect when using SA 800 or SAF 600 welders N F Connections shown for LN 9 wire feeders For LN 8 wire feeders connect A to 75 B to 76 and C to 77 Wurm Connect to desired electrode terminal Work terminal Wire toader 4 cable Mj 2 To cB wire loader M13914 positive 4 24 81 N A A Connect the control cable ground lead to the frame terminal marked near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Extend lead 21A and 21B using 14 or larger insulated wire physically suitable for For 50 Hz Operation the installation An S16586 remote voltage sensing work lead is available for this Disconnect both brown leads purpose Connect it directly to the work piece keeping it electrically separate from from terminal 31B and tape up the weiding work lead
34. si 20100uuoo Jedunp 12 0460 pJeog o d a TE L 7199 The Lincoln Electric Company Cleveland Ohio 44117 1199 LN 9FH OBSOLETE WIRING DIAGRAM Dimension Print METRIC enue 98S p 2 l YS 20 JYS 9 WYS ey seounos ed Jeujo 104 pieog jo epis 1 souenbas JO 4229 SE Jegunu j0 9UU0 1913 199 sjoqui s 4 cy 10 uonoeuuon induy OND Spreoq O d uo juesaud jou esn4 TN ade uld pegoeuuoo peddius eq 04 jedun pjeog 5rd utd a peyoeuuco peddius 499 a 1 enjg pueog or d 3 S peyoeuuoo peddius es 89 0 1eduinf preog org gt 5 DE S31ON pnis AD 2 gt gt Jop uuog 3 gt 223 jeb6u 82 gt 229 pose 5 ie op xa 1 2900 joauoo ces 0 Paay N as 2 veo N 2 a 008 8929 L CET PENN y 17 vi eei a EON vos 9 9 d E EE 208 Pt Li esnJ MOIS d AY 015 56 525 Mia e
35. 1 Burn Back Jumper Plug T13498 3 1 Collar Assembly T12341 1 Button Head Socket Screw T11551 6 1 Key M8776 31 1 Sems Screw T10082 26 1 Key M8776 82 1 Sems Screw T10082 4 1 Plug Button T10397 4 1 Wiring Harness Code 8421 8423 8670 8671 8990 8991 L6323 7 1 Wiring Harness Code 9089 9090 9131 9756 9959 L6323 8 1 Wiring Harness Code 9159 9844 9961 10248 10249 10322 10350 10351 L6323 9 1 Wiring Harness Code 10355 10356 L6323 10 1 Wiring Harness Code 9134 9842 9958 10316 10327 L7202 1 1 Wiring Harness Code 9135 9160 9843 9960 10326 L7271 1 Wiring Harness Code 10353 10354 L7271 1 1 LN9 AND LN9 GMA 01 01 2007 LINCOLN P NOTES LN9 AND LN9 GMA LINCOLN 5 P 127 C P 127 C CONTROL BOX LN9 amp LN9 GMA 2 Roll amp 4 Roll LN9 AND LN9 GMA LINCOLN P 1 28 2002 P 127 C 1 P 127 C 1 Indicates a Change This Printing Use Column 1 for LN9 LN9H LN9 GMA 2 Roll Drive Use Column 2 for LN9 and LN9 GMA 4 Roll Drive Use only the parts marked X in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 1 Cover Assembly Below Code 8200 M12216 1 1 x 1 Cover Assembly Code 8200 to Code 9000 M12216 2 1 1 Cover Assembly Code 9000 amp Above M14851 3 1 1 Cover Assembly 14851 5 1 2 Self Tapping Screw S8025 14 4 3 W
36. 125 1 Number Plate T10726 136 9 1 Number Plate T10726 126 1 Number Plate T10726 137 9 1 12 Lead Clamp T12363 11 4 14 Cable L2286 139 3 15 Box Connector T9639 1 2 16 Cable L2286 256 1 17 Transfer Switch T10800 14 1 18 Nameplate M13677 1 19 Mode Switch T13381 2 20 Caution Decal T13470 1 21 Self Tapping Screw S8025 65 3 22 Hex Jam Nut 1 2 13 6 23 Lock Washer E106A 15 3 24 Plain Washer S9262 1 6 25 Insulating Washer S10773 9 3 26 Insulating Panel 114373 3 27 Insulating Tube T14374 3 28 Connection Strap T8141 3 29 Stud T6931 11 3 30 Flanged Nut T3960 3 91 Grommet T8965 1 32 Reconnect Tag T11590 52 1 33 Control Cable 16378 0 1 39 Control Cable S16677 9 1 X 35 Cable L2286 255 1 36 Contactor Jumper S13472 2 2 LN9 AND LN9 GMA 01 01 2007 P 127 V P 127 V Conversion Kit Chart LN9 4 Roll Drive OUTGOING OUTGOING CONVERSION INCOMING DRIVE ROLL IDLE ROLL GUIDE GUIDE MIDDLE WIRE KIT GUIDE 2 REQ D ASSEMBLY TUBE INSERT GUIDE 7 64 120 amp 2 8 3 0 mmCored KP545 120 KP2123 4 T12057 120 S12722 120 KP2119 1 KP2131 1 KP2129 4 068 amp 3 32 1 7 2 4 mm KP545 3 32 KP2123 5 T12057 3 32 S12722 3 32 KP2119 2 KP2131 2 KP2129 5 Cored amp Solid 1 16 amp 1 6mm Solid KP545 1 16 KP2123 3 13343 1 16 S12722 1 16 KP2117 3 KP2130 3 KP2129 3 1 16 amp 1 6mm KP545 1 16C
37. 13 1 12D Brush Cap Universal Early Design 7 8 27 THD M9655 7A 9 1 12D Brush Cap Universal Present Design 3 4 27 THD M9655 7B o 1 l 12D Brush Cap M13274 7 11 1 X 12E Brush amp Spring Assembly Stature M13312 12 2 12E Brush amp Spring Assembly Universal M12254 1F 2 X 12E Brush amp Spring Assembly Stature M13312 12 2 IX 12E Brush amp Spring Assembly M13274 6 2 12F Insulating Bushing T14058 3 XXIX X 12G Plain Washer S9262 147 3 TXIXTXTX 12H Lock Washer T4291 A 3 12 8 32x1 125 Round Head Screw CF000007 3 XIX 12K Motor Insulator M13479 1 1 IXIXIXIX 12L Insulation Not Shown T13911 1 XIX 12M Speed Clip Not Shown T10982 5 1 IXX LN9 AND LN9 GMA 01 01 2007 This part is obsolete and no longer available P 127 H 2 P 127 H 2 Indicates a Change This Printing For LN9 use parts marked X in Column 1 For LN9F use parts marked X in Column 2 For LNOH use parts marked X in Column For LN9FH use parts marked X in Column 4 ITEM DESCRIPTION PART NO 1123456 71819 13 Gearbox M14310 1 1 13 Gearbox M14310 2 1_ 14A Reed Switch amp Energizer Assembly Below Code 9100 S14623 2 1 XJ 14A Reed Switch Above Code 9100 S12334 43 1 ejeje 14A Reed Switch Above Code 9100 S12334 45 1 14A Reed Switch amp Energize
38. 2 dydy jue ye Al y oaa y gaa ausa y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n Mantenga la cabeza fuara de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail Vermeiden Sle das Einatmen von SchwelBrauch Sorgen Sle f r gute Be und Entiliftung des Arbeitspiatzes Mantenha seu rosto da fuma a Use ventila o e exhaust amp o para remover fumo da zona respirat ria E 5luc Fw TES FRS PEIR BERR S 2475 else
39. 22 Fully Enclosed Wire Reel Support Assembly Includes all above plus L4745 2 1 Hand Crank Assembly See P 107 R 1 X X Wire Feed Unit Handle S13863 1 X X LN XNE Lightweight Wire Reel Support Assembly Includes L5369 2 1 Wire Reel L4604 1 Hand Crank Assembly See P 107 R 1 IX Cage Type Wire Reel Support L5368 1 IX Wire Feed Unit Handle S13863 1 Reel Mounting Shaft Assembly For 2 1 0 Spools Order K162 1 eX Reel Mounting Shaft Assembly Standard M12460 1 IX NOTE 1 To equip an LN 7 with a wire reel cover kit order S14543 Includes items 2 4 through 9 and 13 For LN 7 K376 or K445 Reel S14543 must also be installed when a K1898 1 door is to be installed O This part is obsolete and no longer available 08 25 2009 P 107 P P 107 P WIRE REEL SHAFT 5 7 8 anni 1 2 10 4 M12460 For All LN 6 LN 7 LN 8S 8N 8SE LN 9S 9N 9SE 9NE 9NH and LN 22 use Column 1 For LN 8F LN 9F and LN 9FH use Column 2 Indicates a Change This Printing For SP 200 use Column 3 ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 Reel Mounting Shaft Assembly Includes M12460 1 X Reel Mounting Shaft Assembly Includes M12908 1 Reel Mounting Shaft Assembly Includes M12460 1 1 1 Hex Head Bolt 1 2 13 x
40. 44117 1199 Dimension Print LN 6 LN 8 AND LN 9 DIMENSION PRINT INNERSHIELD ONLY OPTIONAL HANDLE 33 74 M11683 10 11 85D 87Ap The Lincoln Electric Company Cleveland Ohio 44117 1199 LN 9 WIRING DIAGRAM METRIC imension Print L 7197 D DL6v LOILT 30 30IS LNINOdNOD 3ON3n03S 9NIH38WnN ALAYO 318 NNO mmm CON JEYO 1 19 280 HOLIMS 0338 2 IVnNYN ONILYU3dO 335 2 HLIM VS HO 3YS ONY VS S u 5394108 H3MOd H3HLO HO U3MOd JdAL 2 0 NOILOJNNOO S1VLSO3HY JO MOVE NOUS O3M3IA SY SNOLLO3NNOO M38WON AMAVO HOLOJNNOD 12913 334 STOSWAS 121919313 anis SNION IOHO UO193NNOO ET 53005 TIY NO 1N3S3Ud LON G3LO3NNOOSIG St NOILdO 31 30Y1d38 QHYOB 24 39V1 OA 3 gt enr anoo JHL OL G3LO3NNOO S 9d SSINYYH a gt ATIVOH3NOYM de wed Tres 2 d H3MOd 3S Ind TYNOLLdO HOIO3NNOD 5 y gg F e r mA Ex N3HM SI 9074 83994 go 9908 Od 1 we in 30808 Dd MERE De 39VLT0A NO 1435384 LON O N i pes 5 38V9 SHI OL A1LO3HIG SI os 1 Qv31 GNNOYS JHL 15 86 53002 SN ne dr i MO 38 NY 1 16 3009 NO 4351 HOISISIH O N can Ba
41. 6 Shaft Cap T11226 1 7 Output Shaft Assembly S11159 1 9 69 NOTES LN 9 AND LN 9 GMA The Lincoln Electric Company S 16495 Cleveland Ohio 44117 1199 Dimension Print LN 9 AND LN 9H OBSOLETE DIMENSION PRINT S16495 11 14 86B 87Ap M 13660 The Lincoln Electric Company Dimension Print Cleveland Ohio 44117 1199 LN 9F CONTROL BOX DIMENSION PRINT 156 7 e 286 5 o 340 6 R36CSoT FOR MOUNTING M13660 11 6 87E The Lincoln Electric Company Cleveland Ohio 44117 1199 L 6022 Dimension Print LN 9F AND 9FH OBSOLETE WIRE DRIVE UNIT DIMENSION PRINT FRONT BRASS BLOCK FOR GUN CABLE FITTING 214 4 CONNECTORS 1 INCOMING WIRE GUIDE 248 0 CIN 9495 2769 80 8 OF WIRE 7 PIA 4 HOLES FOR MOUNTING 103 8 REF L 6022 87Ap 10 26 79E M 11680 Dimension Print The Lincoln Electric Company Cleveland Ohio 44117 1199 LN 6 LN 8 AND LN 9 DIMENSION PRINT SUBMERGED ARC te 9 24 1 56 m 22 25 RP 42 71 68 00 M11680 10 11 85D The Lincoln Electric Company M 11683 Cleveland Ohio
42. For NR 203 Electrodes 1 Set mode switch to CV Innershield 2 White lead on Control P C Board is connected to Pin Above Code 8200 For Sub Arc 1 Set mode switch to CV sub arc For all Open Arc Processes 1 Set mode switch to CV Innershield December 1981 Assembly and Installation Sec N2 3 3 F The Lincoln Electric Company Cleveland Ohio 44117 1199 CONNECTION OF LN 8 OR LN 9 TO A DC 250 DC 400 AND CV CVI POWER SOURCES To LN 8 LN 9 input Cable plug Power source 1 CV output terminals on DC 250 Negative Positive Electrode cable to wire feed unit To work S17373 8 26 88A Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and position the switch on power source and wire feeder if equipped to proper polarity Also refer to note N G Does not apply to DC 400 below code 9200 with polarity switch N A N B N C N D N E N F Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Extend lead 21 using 14 AWG or larger insulated wire physically suitable for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection Fo
43. KP2125 1 KP2124 1 Wing Screw T9078 3 Can be used for 052 LN9 GMA 4 Roll Drive WIRE INCOMING MIDDLE SIZE CONVERSION GUIDE TUBE DRIVE SPACER OUTGOING OUTGOING INSERT GUIDE KIT ASSEMBLY ROLL 2 REQ D GUIDE TUBE GUIDE INSERT L LOOSE 1023 0255 KP655 025S KP2139 2 M17301 025 114984 KP2125 1 KP2124 1 KP2114 1 030 Solid KP655 030S KP2139 2 M17301 030 T14984 KP2125 1 KP2124 1 KP2114 1 035 Cored KP655 035C KP2139 4 M17302 035 None KP2125 1 KP2124 1 KP2114 1 035 Solid KP655 035S KP2139 4 M14932 2 Reg d T14984 KP2125 1 KP2124 1 KP2114 1 045 amp 052 Solid KP655 052S KP2139 4 S14542 052 2 Reg d None KP1999 1 KP2124 3 KP2114 2 045 052 Cored KP655 052C KP2139 4 514541 052 4 Req d None KP1999 1 KP2124 3 KP2114 2 1 16 Solid KP655 1 16 KP2139 6 514541 1 16 4 None KP2125 3 KP2124 5 KP2114 3 068 3 32 Cored KP655 3 32 KP2139 9 514541 3 32 4 Req d 13342 3 32 2125 5 KP2124 8 KP2114 5 120 Cored KP655 120C T13467 120F M17302 120 None KP2125 4 KP2124 7 KP2114 4 1 16A KP656 1 16A KP2132 1 517092 1 16 2 None KP2137 2 S14349 1 16L KP2115 3 64A KP656 3 64A KP2132 2 517092 3 64 2 None KP2137 3 14349 045 L KP2115 2 035A KP656 035A S21273 3 64F S17092 035F 2 Req d None KP2137 1 S14349 045L KP2115 2 Indicates a Change This Printing Some Drive Rolls Available Only in a Kit LN9 AND LN9 GMA 10 10 2003 LINCOLN P E HR RHR RRR RH GE Sh HH RRR RR
44. N and S Turn the reel until the free end of the electrode is accessible While tightly holding the electrode cut off the bent end Straighten the first six inches and insert the free end through the incoming guide tube Press the gun trigger and push the electrode into the drive roll Inch the electrode through the gun If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a bird nest After the wire picks up inch the electrode out through the gun cable and gun assembly WARNING The electrode and drive mechanism are hot to ground while inching with the gun trigger NOTE On Codes above 7980 the Trigger Interlock and Hot Cold Wire Feed Switch should be in the center position In this position the wire may be fed electrically cold 2 When using the extension assembly Models NE and SE Slide the ingoing guide tube of the hand crank to the forward position Remove start end of coil from hole in wire reel cover straighten the first six inches or so of the wire and then insert this end in the ingoing guide tube Push a foot or so of wire through Now pull the ingoing guide tube back to the rear position and rotate it 90 so that it will remain in this position during the cranking operation Pull the plastic hand crank handle to the out position in the arm Pull the shaft and drive roll assembly to the out position with the l
45. N3 5 3 continued Standard mounting screw Selector switch housing 8 Mounting plate 8 32 x 3 4 long nounting screw Switch mounted on left side of gun Selector switch housing Mounting plate 8 32 x 3 4 long mount ng screw Standard mounting screw Switch mounted on right side of gun 8 Tape selector switch control cable to gun cable as reguired Check that the control cable is plugged into the dual procedure control box Magnum K470 K471 and K497 GMA Guns Remove the two handle screws shown below Fasten the switch mounting plate that is sent loose to the gun handle using the 10 24 x 1 25 and 6 32 x 1 00 screws sent with the kit The mounting plate can be mounted on either side of the gun handle Remove the switch mounting plate that is attached to the switch Fasten the switch to the mounting plate that was added to gun handle using the 8 32 x 25 screw removed from the switch and an 8 32 x 25 screw sent with the kit remove 2 screws OPERATION Set selector switch to position 1 and use Procedure 1 dials on dual procedure kit to preset wire speed and voltage per standard LN 9 operation Then set selector switch to position 2 and use Procedure 2 dials on dual procedure kit to preset wire speed and voltage Unit will now weld at settings for Procedure 1 when switch is in position 1 or settings for Procedure 2 when switch is in p
46. Ouincy Ma 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated eguipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered eguipment 8 a Turn off input power using the disconnect switch at the fuse box before w
47. Put transfer switch in same polarity on feeders position Place mode switch on power source to CV innershield and place each mode switch on dual process control in the position required by process used with wire feeder Connection shown for negative polarity For positive polarity reverse electrode and work cables connected to power source output studs For DC 600 codes below 8200 only 1 When using two LN 9 wire feeders connect jumper on the power source terminal strip as shown between terminals N amp P 2 When using two LN 8 wire feeders connect jumper to power source terminals N amp 5 3 Wire feeder amp MUST BE OF SAME MODEL M13917 11 2 79 DC 600 CONNECTION TO TWO LN 8 s OR TWO LN 9 s FOR OPPOSITE POLARITY OPERATION N A Welding cables must be of Welder control cable NB B Welding lead Stud on back ol contactor kit To work Dual i ox 2 DC 600 RE ET ag N B i jeo rh 1 N D A s 8 E 8 A oli lolio A a elle B N E ME 4 totol 4 l MP to a 2 2 wee a 32 falu je e 1 ai d NB Bi Ng a AS To positive Den output stud on output stud on N F power source power source NG Wire leader Ele
48. Reel and Flux Tank Assembly N3 320 K306 Wire Reel and Flux Tank Assembly N3 321 K445 Wire Reel Assembly tetendit tete emer E andit ioter itid 3 3 22 Dual Process ti daten etin co E CE N3 5 1 K318 Dual Process Contactor rettet LL N352 K3 19 Dual Proc dure aiu a a WAG GU 3 5 3 K442 1 amp K442 2 Pulse Power Feeder Conversion Kit N3 5 4 K392 Power Extended Wire Drive sete AL entree ettet I LL AAA N3 5 5 K425 Gas Solenoid Kit iu Gn Y ipe tene tte date rete edere dede N3 5 6 R437Gas Solenoid Kit aee ertt m ica t nra et GWY Y Ne WYF ver v EROR N3 5 6 Sec N4 Operating Instructions Control Adjustments and Loading the Machine Wire Reel Brake 50 60 Pound Reel Mounting eines Sec N4 4 1 Drive sista eo Area Sec N4 4 2 Electrode Polarity Switch eese s ud tu ett rep Sec N44 3 conte mus ucla gd a GR YO Sec N A 4 4 96Au Index The Lincoln Electric Company Cleveland Ohio 44117 1199 Trigger Interlock Switch eonen ui reete o E e te YN Sec N4 4 5a Trigger Interlock and Hot Cold Wire Feed Switch cree Sec N4 4 5b Direction of Wire Feed Switch inner Sec N4 4 5c Digital nine Ur GWAN te Y OW a Sec N4 4 6 Meter Reading Switch Volts and Wire Speed Controls I IU UL AN
49. Solenoid Valve Kit Above Code 9100 Only Not Reg d on GMA Models Order K425 Pulse Power Feeder Conversion Kit Below Code 9100 Only ns ier te Order K442 2 Pulse Power Feeder Conversion Kit Above Code 9100 Only s dtu Order K442 2 Gun amp Cables K112 and K113 Squirt Guns amp Cables P 103C K112 and K113 Gun Assembly P 103 D K114 Squirt Gun and Cable P 103 E K115 Squirt Gun and Cable P 103 F K116 Squirt Gun and Cable P 103 G amp P 103 H K126 Squirt Gun and Cable P 103 J amp P 103 K Indicates a Change This Printing LN 9 AND LN 9 GMA LINCOLN HH HHH P 127 B 2 MISCELLANEOUS ITEMS These Items Are Not Illustrated P 127 B 2 Indicates a Change This Printing ITEM DESCRIPTION PART NO GTY 1 2 6789 Work Jack T14280 1 Input Amphenol S12021 12 1 Output Amphenol S12021 3 1 Heat Sink LN9 LN9H Part of Motor M13579 1 Insulator LN9 amp LN9H Part of Motor S16267 1 Drive Motor Cover LN9F amp LN9FH Part of Motor S16718 1 Grommet LN9F amp LNOFH Part of Motor S10255 12 1 Hose Nipple T15008 1 Inert Arc Nut T15007 1 1 Handle Optional S13863
50. circuit and connection For convenience these extended each lead Untape both red 21A and 21B leads should be taped to the welding work lead Each lead must leads and connect to 31B be connected directly to the work and leads must not be connected together The Lincoln Electric Company Assembly and Installation Cleveland Ohio 44117 1199 Sec N2 3 3 R K318 DUAL PROCESS CONTACTOR KIT R3S AND SAM CONNECTION TO TWO LN 8 s OR TWO LN 9 s FOR SAME POLARITY OPERATION tn N A Welding cables must be of proper capacity for the current omite and duty cycle of immediate Lu NBB Welder control cable 21A 21B idum and future applications 7 re N B Bolt and tape connections Tape up leads N D Put transfer switch in same Connect a same numbered polarity on feeders position lamina power sourco rae N E Mode switch has no effect when using R3S or SAM Uc i welders A Non N F Refer to appropriate wire NG feeder to power source mem bed connection diagram M dyw i N G Connections shown for MM eh LLL negative polarity For positive e Wire oder polarity reverse electrode and cabia cable work cables connected to V ma power source output studs on A wia Ta 8 wie leader R3S welders On SAM welders electrode polarity is set by N A A
51. clean the liner soak it in degreasing solvent for one hour Flex short lengths of the liner around a 3 diameter mandrel to spread the coil turns and blow compressed air across and between the turns at 90 to the liner axis This is needed to remove particles from between the turns Do not blow compressed air through the master cable Be sure the outside diameter of the liner is clean when inserting it into the cable Insert by short sections about 3 in length Do not let the liner bend sharply because this may cause a permanent bend in the liner Sec N6 2 4 GUN NOZZLES 1 Replace worn contact tips as reguired 2 Replace worn spring liners in nozzles The life of the liner can be doubled by rotating liner 180 The liner can be pulled out the back end of the nozzle by wedging the blade of a small screwdriver in the I D and pulling 3 Internal parts of nozzles can be removed and replaced by removing the internal hollow lock set screw from the contact tip end of the nozzle with a 5 32 or 3 16 Allen wrench The ceramic insert and retainer will normally fall out the end of the nozzle but if they do not gently drive the spring liner towards the outgoing end of the nozzle The Lincoln Electric Company Cleveland Ohio 44117 1199 See appropriate parts list page for construction details and replaceable parts For those guns where similar nozzles are used for different wire sizes note the identifying wire size that is stenciled
52. connection with electrical tape 5 Electrode Routing The electrode supply may be either from 50 60 1b 22 5 27 2 Kg reels 25 30 lb spools Speed Feed drums or Speed Feed reels a The electrode must be routed to the wire feed mechanism so that the bends in the wire are at a minimum and also that the force required to pull the wire from the reel into the wire feed mechanism is kept at a minimum b The electrode of course is hot when the gun trigger is pressed and must be insulated from the bottom c If more than one feeder head shares the same boom their wire reels must be insulated from each other and insulated from their mounting structure October 1991 Sec N2 2 9 GUN AND GUN CABLE 1 General The LN 9 is used with various guns Use the gun recommended for the wire type solid or Tnnershield and size to be used 2 Gun Cable LN 9 to Gun Lay the cable out straight Insert the male end of the welding conductor cable into the brass block on the front of the LN 9 Make sure it is in all the way and tighten the locking screw with a 3 16 4 8 mm Allen wrench or thumbscrew if provided Keep this connection clean and bright Insert the control cable polarized plug into the receptacle next to the coupling October 1991 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC N2 3 ELECTRICAL INSTALLATION WARNING Do not operate with covers re
53. convenience this extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 9 s which have a direct work lead jack If using an older LN 8 control cable connect lead 75 to 75 on terminal strip connect lead 76 to 77 on terminal strip connect lead 77 to 76 on terminal strip Then jumper terminal strip 75 to 76 per diagram Upper terminal strip 75 76 amp 77 may not appear on older R3S machines and therefore is not compatible for use since there will be no adjustment of voltage by the LN 9 The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual White jumper on voltage board To Pin F for open arc process or to Pin S for sub merged arc process Blue jumper on voltage board later units only or on start board earlier units to Pin NOTE Refer to Sec N2 3 2 for Control Board pin placement The Lincoln Electric Company Assembly and Installation Cleveland Ohio 44117 1199 Sec N2 3 3 C CONNECTION OF LN 9 TO A SAM MOTOR GENERATOR OR ENGINE WELDER Power Source f 6 N A Welding cables must be of proper capacity for the current and LN 9 control cable p duty cycle of immediate and future applications mE N B Extend lead 21 using 14 or larger insulated wire physically roS To LN 9 input cable plug suitable for the installation An S16586 rem
54. heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101
55. no longer available NSS Not Sold Separately LN 9 AND LN 9 GMA LINCOLN P 05 06 2006 P 127 J 2 P 127 J 2 ITEM DESCRIPTION PART NO GTY 1 67819 20 Gear Box Mounting Plate S20331 1 21 1 4 20x 625 Flat Head Screw CF000345 2 X 22 Swing Arm Assembly Includes M16445 2 X 22 Bearings amp Shaft Assembly T13244 1 1 X 22B Roll Pin Not Shown T9967 25 1 X 22C Plain Washer Not Shown S9262 60 1 X 22D Pin M8809 122 1 X 22E Spring T10247 11 1 X 22F Plain Washer S9262 3 2 X 22G Socket Head Screw T9447 21 2 X 22H Release Assembly S19965 1 X 22J Knob 19922 1 X 22K Swing Arm M16446 1 X 22L Pivot Block Shaft Not Shown 19921 1 X 22M Spacer Not Shown 20244 2 X 22N Tension Rod S19920 1 23 Pin S19828 1 X 24 Connection Box Assembly LN9F GMA 4 Roll M15238 1 1 X Not Shown Female Connector T11591 3 1 X Solenoid Valve Assembly M15234 1 Number Plate T10726 153 1 X Hose Clamp S10888 35 1 Connector T14557 3 1 X Connector and Lead Assembly 13100 73 1 Terminal Strip S14530 10 1 X Terminal Strip S14872 1 1 X Warning Label T9274 4 1 X 25 Swing Arm Spacer S19923 1 LN9 AND LN9 GMA 02 13 2006 LINCOLN P NOTES LN9 AND LN9 GMA LINCOLN P P 127 K P 127 K WIRE DRIVE MOTOR amp GEAR BOX ASSEMBLY LN9 GMA amp LN9F GMA 10 26 2007 Old Style 2 Roll LN9 AN
56. over range meter readings of E EE which indicates the HI range with single decimal place resolution should be used The procedure adjustments can be made before or during the weld This feature permits the operator to set welding voltage and wire speed before welding and without assistance The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N4 4 7 continued Once set the control circuits of the LN 9 will continuously monitor the volts and wire speed and correct any deviation from the set value so there will be negligible change Should the range of the power source output voltage be such that the LN 9 circuit cannot keep the arc voltage as set the LN 9 will stop welding shortly after the arc is struck See Item F in the Troubleshooting Section N6 April 1987 Sec N4 4 8 SET ACTUAL PUSH BUTTON After the weld has been started the ACTUAL voltage or wire speed can be read by pressing the Set Actual push button The Meter Reading switch must be set in the desired position When the push button is not being operated the meter continues to read the SET value March 1979 Sec N4 4 9 ELECTRODE HOT COLD SWITCH LN 9F Code 7980 only See N4 4 5b for Codes Above 7980 The switch permits feeding the wire electrically hot or electrically cold When the switch is in the upper position and the trigger is pressed the electrode will feed hot and when it contacts the work the welding will be init
57. procedure can be used on other power sources For example if the LN 9 keeps shutting down and the other possible causes have been checked adjust the SET voltage higher and or lower than the desired voltage If the LN 9 continues to weld at one of these voltages it can then be determined what change in the range controls of the power source are reguired so it can supply the desired voltage July 1981 P 127 P 127 PARTS LIST FOR LN 9 AND LN 9 GMA This parts list is provided as an informative guide only This information was accurate at the time of printing However since these pages are regularly updated in Lincoln Electric s official Parts Book BK 34 always check with your Lincoln parts supplier for the latest parts information LN 9 AND LN 9 GMA 1 18 96 LINCOLN 5 P 127 A P 127 A LN 9 AND LN 9 GMA SGUIRT WELDERS Sguirtgun and Cable Assembly P 103 Series LN 9 Wire Feeders and Options LN 9 9H Control Box 2 Roll 8 4 Roll Drive P 127 C Hinged Door Assembly 2 Roll amp 4 Roll P 127 D Base Platform 2 Roll amp 4 Roll P 127 E Control Panel Instrument Assembly P 127 F Panel eu y e tan Eu A wr usd YA Par fet rupe ie gat ete P 127 G Wire Drive
58. runs and the welding circuit is energized only when the gun trigger is pressed The operator must hold the trigger in from the start to the finish of the weld To stop the arc release the trigger and lift the gun from the work With the Trigger Interlock switch on the operator holds the trigger until the arc is established then the trigger can be released When the weld is completed the operator raises the gun from the work to break the arc This stops the wire feed and deenergizes the welding circuit February 1980 Sec N4 4 5b TRIGGER INTERLOCK AND HOT COLD WIRE FEED SWITCH Above Code 7980 This three position switch performs a dual function In the center position the wire may be fed electrically cold In the down position the wire is electrically hot when feeding and the trigger circuit is controlled only by the trigger In the up position the wire is electrically hot when feeding and the trigger circuit remains energized once the arc is established without holding the trigger until the arc is broken February 1980 Sec N4 4 5c DIRECTION OF WIRE FEED SWITCH Above Code 7980 This switch enables the operator to feed the wire in either direction by pressing the gun trigger If backing wire out it is recommended that cold wire feed be used See Sec N4 4 5b February 1980 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N4 4 6 DIGITAL METER A three digit meter is provi
59. spring item 9 out of the hole in the trigger bar item 10 2 Loosen the gun tube clamping screw item 3 and remove the gun tube A slight back and forth twisting action will help 3 Remove both the screws item 21 which hold the two plastic halves together After these screws have been removed the left and right gun mounts items 6 and 11 can be separated and the remaining parts the nozzle item 4 gun hanger item 18 and the flux tube assembly item 7 can be removed To disassemble the gun handle from the cable proceed as follows 1 Remove the flux hose from the gun 2 To remove the flux tube item 29 take out the two flat head screws item 32 The flux tube item 29 can then be removed by pulling it straight back Be careful not to damage the ends of the tube 3 To remove the cable item 31 from the handle take the snap ring item 34 off the end of the brass connector With the clamping screw item 33 loose the cable item 31 can then be pulled back out of the handle 4 To remove the switch remove the three round head screws item 37 This will allow the switch mounting plate item 36 to be removed from the fiber handle Remove the two small screws item 40 which hold the switch to the plate The leads that go to the switch can then be unsoldered 5 To remove the clamping ring item 26 from the handle remove the screw item 35 and tighten the clamp screw item 33 The clamping ring may then
60. to wire feed unit y NB To work Power source Tape up bolted connection Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and reverse the control switch at the power source and the polarity switch on the LN 9 Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip or to an unpainted frame screw The power source must be grounded properly S16285 6 28 85N POWER SOURCE SETTINGS Turn Power Source OFF R3S 400 R3S 600 and R3S 800 Obsolete a b Connect electrode lead to terminal of desired polarity Set toggle switch to same polarity as the electrode cable connection Set toggle switch to Remote Install voltage triangle to a position as close as possible to desired arc voltage April 1987 N D N E N F On earlier R3S 400 600 amp 800 machines 67 amp 1 terminals were also on the terminal strip Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Extend lead 21 using 14 or larger insulated wire physically suitable for the installation An S 16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For
61. trigger will not feed wire Meter is on and reads SET value of Volts or Wire Speed Gun trigger works and arc can be struck Unit then shuts down while welding or voltage output too low to establish arc LN 9 ACTUAL VOLTS meter reading is low or zero when trigger is closed Poor arc striking with sticking or blast offs weld porosity narrow and ropy looking bead or electrode stubbing into plate while welding Contact tip wom or incorrect size Worn or undersized work cables or poor work connections Loose electrode connections Voltage Control Response not properly set for power source and process Circuit breaker is tripped Field circuit fuse blown No 115V AC supply from power source Internal motor thermal protector ha tripped Grounding lead protector circuit has tripped Wire feeder or power source Electrode Polarity switches are not set properly Direct Work Lead Plug not fully engaged into wire feeder with jack or clip not connected to work Power source voltage control not set for REMOTE LN 9 control cable leads or weid cables misconnected to power source 1 8 A fuse on Voltage board s blown Welding power source is unable to supply SET voltage Improper procedures or techniques Improper wire feed acceleration setting for process Voltage Control Response not properly set for
62. voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience these extended 21A and 21B leads should be taped to the welding work lead Each lead must be connected directly to the work and leads must not be connected together 910c N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N B Bolt and tape connections N C Tape up separately N D Put transfer switch in opposite polarity on feeders position N E Mode switches on contactor kit are not functional when used with the DC 400 N F To make feeder positive polarity and B feeder negative polarity reverse electrode cables connected to power source output studs M14551 1 20 89B For 50 Hz Operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation SEC N3 OPTIONAL FEATURES Sec N3 3 1 K178 1 MOUNTING PLATFORM LN 9N OR 9HN Obsolete ON IDEALARC R3S DC TYPE AND CV POWER SOURCES This is a turntable type platform for mounting the wire feeder and reel assembly on the top of Idealarc power sources including new CV power sources Bolt the platform on the lift bail per instructions supplie
63. when using any stickout extension March 1979 Sec N4 4 17 STARTING CHARACTERISTICS ACCELERATION SETTING The LN 9 has the capability of optimum starting for different processes This is accomplished by designing the LN 9 to start with two different speeds of controlled acceleration As shipped the unit is connected for fast acceleration which is the best for most situations except when using long electrical stickouts If the electrode being used does not give satisfactory starting because of stubbing or blasting off a slower acceleration can be obtained by modifying the LN 9 as follows 1 Turn off the control power to the LN 9 at the power source 2 Remove the screws holding the LN 9 control section cover in place and swing open 3 Move the jumper plug on the control P C board from pin F to pin 5 4 Reassemble Operating Instructions Sec N4 4 17 continued START VOLTAGE TRIM The start voltage is the voltage provided by the welding power source before establishing the welding arc This start voltage setting is a function of the open circuit voltage characteristic of the power source the SET value of the weld voltage and the start voltage trimmer R41 setting on the LN 9 Voltage PC Board As set at the factory the start voltage trim level is typically about 20 higher than the LN 9 SET level This generally gives good starting for steel cored and MIG processes using CO2 or
64. will now weld at its reguired polarity and procedure when the gun trigger is actuated Do not try to weld with both units simultaneously or pull the trigger of one wire feeder when the other is welding because the welder output will be shut off TROUBLESHOOTING Electrode feeds but is electrically cold Poor bead shape or arc response when using DC 600 power source No control of power source Poor starting when using DC 600 below Code 8200 Poor starting or burn back on the first weld when changing wire feeders Transfer switch is n wrong position Place in correct position Mode switch in wrong position on dual process contactor kit or on welder Place in correct position Power source voltage control switch not set to remote Set power source per its instruction manual Defective relay in kit Check operation of 1CR and replace if defective Defective wire feeder control rheostat Refer to operating manual improper connection on power source terminals N P and S Refer to connection diagram to connect properly Relays not transferred properly Actuate gun trigger once before starting when changing from one wire feeder to another April 1987 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation OPTIONAL FEATURES CONT D Sec N3 5 K319 DUAL PROCEDURE KIT The dual procedure kit is a transfer device that enables an operator to choose one of two procedures
65. wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires NOTE Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in backlashing of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded 6 Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing it across the reel hub 7 Turn the reel until the free end of the electrode is accessible While tightly holding the electrode cut off the bent end Straighten the first 6 inches and cut off the first inch Insert the free end thru the incoming guide tube Press the gun trigger and push the electrode into the drive roll Inch the electrode thru the gun If the electrode is not properly straightened it may not feed or may not enter the outgoing guide tube causing a bird nest WARNING The electrode is hot to ground while inching with the gun trigger NOTE On Codes above 7980 the Trigger Interlock and Hot Cold Wire Feed Switch should be in the center position In this position the wire may be fed electrically cold January 1989 Sec N4 4 11 WIRE REEL LOADING Readi Reels and 10 to 30 Pound Spools To mount a 30 16 Readi Reel package remov
66. with a selector switch that is attached to a semiautomatic gun handle Simply changing the selector switch position will set the wire feed speed and voltage to the values chosen for each procedure The unit can be used with an LN 9 LN 9H Obsolete LN 9F or LN 9FH Obsolete wire feeder A small control box is attached to the wire feeder control box and is connected to the gun mounted selector switch with a control cable The switch can be attached to the side of the gun handle of a K112 K113 K115 K126 K206 or K289 gun and cable assembly When used with an unit a K302 17 feet standard length extension cable is reguired to extend the control cable to the control box The length reguired is the same length as the control box to wire feeder cable Maximum versatility is obtained when the wire feeder is connected to a DC 250 400 or 600 When used with a SAM or R3S power source the voltage range between the two procedures required may be outside the range covered by the remote control and it would therefore be impossible to set the procedure without adjustment at the power Source INSTALLATION Nameplate Security Panel Control Box Door Latch Installing dual procedure control box Pictures show LN 9 control box 1 Turn off all input power and remove security panel nameplate and latch from LN 9 2 Remove screws that hold the LN 9 control box door in place and open to expose back of rheostat panel shown
67. 0 T12341 1 38 Collar Assembly Above Code 10300 S21193 1 39 Button Head Socket Screw T11551 6 1 X X 40 Feed Unit Mounting Screw Not Shown M12616 1 X 41 Round Head Screw Not Shown 1 4 20x 625 3 X 42 Lock Washer Not Shown E106A 2 3 X 43 Hex Nut Not Shown 1 4 20 3 X Cover Black End of Motor S16718 1 XIX LN9 AND LN9 GMA 01 01 2007 LINCOLN P NOTES LN9 AND LN9 GMA LINCOLN P P 127 J P 127 J WIRE DRIVE MOTOR amp GEAR BOX ASSEMBLY LN9 GMA amp LN9F GMA 4 Roll LN9 AND LN9 GMA LINCOLN P 1 28 2002 P 127 J 1 P 127 J 1 ITEM DESCRIPTION PART NO GTY 1 2 67819 Gear LN9F GMA 4 Roll Includes G2262 3 1 X Gear Box Asbly LN9 GMA 4 Roll Includes G2262 2 1 1 Drive Motor Asbly LN9 GMA Includes M15078 1 1 X 1 Drive Motor Asbly LN9F GMA Includes M15078 3 1 X 1A Drive Motor Includes NSS 1 X 1B Brush amp Spring Asbly Universal Electric M13274 6 2 X 1B Brush amp Spring Asbly Specialty Motors M16718 F o 2 X 1B Brush amp Spring Asbly Stature Electric M15114 1K 2 X 1C Brush Cap Universal Electric M13274 7 2 x 1C Brush Cap Specialty Motors M14907 1G 2 X 1C Brush Cap Stature Electric M15114 1L 2 X 1D Plain Washer Not Shown S9262 70 1 X 1E Pinion Gear S17980 1 1 X 1F Roll Pin T9967 33 1 X
68. 0 from the center of the potentiometer hole so the head is on the backside of the panel inside the control box 5 Remount the control potentiometer with the fiber spacer under the locknut then close and secure the control panel 6 Replace the felt seal around the fiber spacer so the 4 screw protrudes between the fiber spacer and the felt seal 7 Turn on the LN 9 input power and set the desired procedure by rotating the potentiometer shaft 8 Carefully replace the control knob so the 4 screw inserts into the center of the shorter length channel on the back of the knob for about 3 of the total range of control or the center of the longer length channel for about 15 of the total range of control 9 With finger pressure on the knob against the felt seal carefully retighten the Knob set screw NOTE Steps 7 thru 9 will have to be repeated if it is desired to change the set procedure to a value outside the selected 3 or 15 control range limit February 1982 The Lincoln Electric Company Cleveland Ohio 44117 1199 Maintenance SEC N5 GENERAL MAINTENANCE AAWARNING Do not operate with covers removed Turn off power source before installing or servicing Do not touch electrically hot parts ELECTRIC SHOCK can kill urn the input power to the welding power source off at the fuse box before working in the terminal strip Keep away from moving parts lt ay MOVING PARTS can i
69. 0 3 3 X Self Tapping Screw S8025 71 3 X 5 Transformer Assembly S16282 1 X 5 Transformer Assembly Used with Trigger Board S16282 1 1 6 Power Board Relay S13929 6 1 X LN9 AND LN9 GMA 01 01 2007 LINCOLN P P 127 T P 127 T Conversion Kit Chart LN9 GMA 2 Roll Drive CONVERSION INCOMING DRIVE OUTGOING OUTGOING DRIVE ROLL WIRE KIT GUIDE ROLL GUIDE TUBE GUIDE INSERT SPACER 068 5 64 Cored KP653 3 32 KP2139 8 S14541 3 32 2 Req d KP2125 5 KP2125 8 S13342 3 32 062 1 16 Cored or Solid KP653 1 16 KP2139 5 S14541 1 16 2 Req d KP2125 3 KP2124 5 None 045 amp 052 KP653 052C KP2139 3 S14542 052 KP1999 1 KP2124 3 None 045 052 Cored KP653 052C KP2139 3 M17301 2 Reg d KP1999 1 KP2124 3 None 023 035 Solid KP653 035S KP2139 3 M17301 035 KP2125 1 KP2124 1 T14984 030 Solid KP653 030S KP2139 1 M17301 030 KP2125 1 KP2124 1 114984 035 KP653 030C KP2139 3 M17301 030 KP2125 1 KP2124 1 T14984 035 Solid KP653 035S KP2139 3 M17301 035 KP2125 1 KP2124 1 T14984 7 64 Cored KP653 7 64H KP2139 8 M17302 120 KP2125 4 KP2124 7 None 120 Cored KP653 120C KP2139 7 M17302 120 KP2125 4 KP2124 7 None 1 16A KP654 1 16A KP2139 5 S17092 1 16A KP2125 3 KP2124 5 Wing Screw T9078 3 3 64A KP654 3 64A KP2139 3 17092 035A KP1999 1 KP2124 1 Wing Screw T9078 3 035A KP654 035A KP2139 1 17092 035A
70. 0 Hex Nut CF000017 1 X 18 Locator Bushing Not Shown S19825 1 X 19A Collar Assembly Below Code 10300 T12341 2 X 19A Collar Assembly Above Code 10300 S21193 1 19B Button Head Socket Screw T11551 6 2 X 19C Key Below Code 10300 M8776 31 2 X 20A Reed Switch Energizer M16370 1 X 20B 1 2 13x 75 Hex Head Cap Screw 00020 1 X 21A Reed Switch Assembly 12334 43 1 X 21B Self Tapping Screw S8025 13 1 X 21C 1 2 13x1 75 Hex Head Cap Screw CF000026 1 21D Plain Washer S9262 1 1 X 21E Flange Nut T3960 1 X 21F Lock Washer Not Shown T9695 8 1 X 21G 1 2 13 Hex Jam Nut CF000054 1 21H Insulation S18169 1 X 22A Gearbox Mounting Plate S19831 1 X 228 5 16 18x 75 Hex Head Cap Screw Not Shown CF000040 4 x 22C Plain Washer Not Shown S9262 121 4 X 22D Lock Washer Not Shown E106A 14 4 X 23 Insulation M16372 1 X LN9 AND LN9 GMA 01 01 2007 LINCOLN NOTES LN9 AND LN9 GMA LINCOLN P P 127 M L7201 6 28 85M CONTROL BOX LN9F LN9FH amp LN9F GMA P 127 M LN9 AND LN9 GMA LINCOLN P 1 96 P 127 M 1 P 127 M 1 Indicates a Change This Printing
71. 0 thru 1 16 0 9 thru 1 6 mm wires at fast wire feed speed when there is a tendency for wire overrun 2 When the semiautomatic gun is mounted in a fixture or on the Squirtmobile in such a manner that it cannot be lifted from the work at the end of the weld TRIGGER SET TO SAME i POLARITY AS LL ELECTRODE OFF Front panel of the LN 9F without K202 Piug button is removed when installing K202 kit SET TO SAME TRIGGER POLARITY AS INTERLOCK ELECTRODE H SQUIRT WELDER pren LN 9F WIRE FEEDER SFT Front panel of the LN 9F with K202 installed Attach decal as shown in photograph This kit delays shutting off the power source output allowing the electrode to be melted while the wire feed motor is stopping at the end of the weld The delay time is adjustable for optimum burnback for different wire sizes processes procedures etc The operator must release the trigger slightly before he wants the weld to stop and hold the gun in position until the arc goes out The Lincoln Electric Company Cleveland Ohio 44117 1199 Installation instructions are shipped in the kit NOTE The K202 does not delay the opening of the auxiliary eguipment contacts see Sec N3 3 6 If it is desired to continue power to auxiliary eguipment during the K202 burnback time this can be accomplished only if using an R3S DC 400 or DC 600 power source by connecting the 115 vol
72. 1 X 10A 6 32x 375 RHS CF000003 1 X 10B Lock Washer E106A 13 1 10C 6 32 HN CF000005 1 X 11 Grommet S10255 12 1 x 12 Transformer Asbly Part of M15098 3 Harness S16282 1 13 Grommet S10255 14 1 14 Power Board Connection Diagram LN9 amp 9H Only T14258 1 X 14 Power Board Connection Diagram LN9 amp GMA Only 115050 1 X 15 Relay Mounts on Power P C Board S13929 6 1 IX Note When ordering new printed circuit boards indicate the dash number of the Old board that is to be replaced This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters The dash number brackets have purposely been left blank so as to eliminate errors confusion and updates Q This Part is Obsolete and No Longer Available LN9 AND LN9 GMA LINCOLN 5 10 20 2006 P 127 G P 127 G METER PANEL ASSEMBLY we RS SANT e LN9 AND LN9 GMA LINCOLN 5 P 127 G 1 P 127 G 1 Indicates a Change This Printing For Codes Below 8000 use parts marked X in Column 1 For Codes 8000 to 8700 use parts marked X in Column 2 For Codes Above 8700 use parts marked X in Column 3 ITEM DESCRIPTION PART NO 11213 4 5 6 7 819 1 Meter Housing Below Code 9900 L4753 9 1 1 Meter Housing Above Code 9900 L4753 1 1 2A Actu
73. 1 00 1 2 Lock Washer E106A 15 1 4 Brake Assembly Includes S14882 1 X 4 Brake Assembly Includes S14882 1 1 7113519 1 Cotter Pin S10750 19 1 5 Plain Washer 1 38 O D S9262 14 1 5 Plain Washer 1 50 O D S9262 119 1 7 Insulator Bushing T14816 1 X X 8 Insulating Washer S10773 52 1 X X 9 Wire Reel Shaft Assembly 16253 1 X X 9 Wire Reel Shaft Assembly 15492 1 X 10 Roll Pin T9967 9 1 11 Knob 11038 1 si LN 6 and LN 7 welders built before November 1972 did not have the adjustable brake Item 4 If a shaft or fixed brake assembly is needed order the M12460 Assembly 4 19 2000 P 107 R P 107 R HAND CRANK ASSEMBLY LN 6 LN 7 LN 8 and LN 9 L4703 For All LN 6 LN 7 LN 8S 8N 8SE LN 9S 9N 9SE 9NE 9NH and LN 22 use Column 1 For LN 8F LN 9F and LN 9FH use Column 2 Indicates a Change This Printing For SP 200 use Column 3 ITEM DESCRIPTION PART NO GTY 67 89 Hand Assembly Includes L4703 0 1 1 Plain Washer S9262 120 1 2 Hex head Screw 3 8 16 x 50 1 3 Bracket Assembly M10965 9 1 4 Lever Arm Stop pin T9967 4 1 5 Drive Screw S8025 7 2 6 Tension Spring T11514 1 7 Guide Tube S13686 1 8 Spacer Washer S9262 56 1 9 Conductor Block S13687 1 10 Hex head Screw 1 2 13 x 75 1 11 Shaft T12650 1 1 12 Roll Pin T9967 31 1 13 Drive Roll S12805 1
74. 1 Flux Tank G1204 1 1 2 Decal T11182 1 3 Tank Cover S11461 1 XXX 4 Instrument Mounting Bracket S12741 1 5 Hex Head Screw 1 2 13 x 1 25 2 XXX 6 Lock Washer E106A 5 8 7 Hex Nut 1 2 13 4or5 8 Pipe Nipple T9959 11 1 9 Check Valve T11130 1 9 Check Valve T14410 1 10 Pipe Nipple T9959 7 1 Xle 10 Pipe Coupling T12390 1 1 11 Street Elbow T9958 2 4 12 Caution Tag T11416 1 XXX 13 Air Line Filter S11060 1 14 Water Separator M8985 1 1 15 Strainer S16628 1 1 16 Hex Head Screw 1 2 13 x 75 5 17 Compression Elbow S7531 1 XXX 18 Bleeder Line For LN 4 or LN 5 Also Order Items 35 amp 36 T12995 1 20 Flux Tank support S12737 3 21 Copper Line For LN 4 or LN 5 Order 54893 65 o 54893 61 1 21 54893 66 1 22 Male Connector T11167 2 23 Pressure Regulator S11028 1 24 Reducing Bushing T9948 1 25 Pressure Gauge S11395 1 XXX 26 Clamp 12740 1 27 Hex Head Screw 1 2 13 x 2 75 1 28 Adaptor T11248 2 29 Screen 111249 2 XXX 30 Safety Valve T11394 1 31 Street Tee T11393 1 X 32 Cap Gasket T11225 1 1 33 Outlet Tube Cap S11155 1 34 Outlet Assembly S12739 1 XXX 35 Union T12754 1 XXX 36 Flared Copper Tube T12755 1 37 Flux Hose T10642 81 1 Xle 37 Flux Hose 8 Ft T10642 80 1 x X 37 Flux Hose 11Ft Boom T106
75. 14 Conical Spring T12648 1 15 Idle Roll 1 16 thru 120 T12556 4 1 17 Incoming Guide Tube T12654 1 18 Retaining Ring S9776 1 1 19 Flat Head Screw 5 16 18 x 1 25 1 20 Handle S13397 1 21 Crank Arm Assembly S13392 1 22 Lever Arm Assembly S13404 1 23 Retaining Ring S9776 3 1 24 Fiber Pin T8433 1 25 Socket Head Cap Screw T9447 10 9 2 26 Set Screw S11604 11 1 27 Hex Head Screw 3 8 16 x 1 25 2 Insulating Tube T7305 4 2 Insulating Washer S10773 19 2 Plain Washer S9262 120 2 Lock Washer E106A 4 2 Hex Nut 3 8 16 2 Insulating Pad T8477 12 1 Q This part is obsolete and no longer available 01 30 2003 P 107 S P 107 S FLUX TANK LN 6 LN 7 LN 8 and LN 9 BW x A gt TA ER WD reat IU 1 4695 4 9 19 80 3 15 82 P 107 S 1 P 107 S 1 Use Column 1 for Flux Tanks with Safety Valve on Outlet Assembly Use Column 2 for Flux Tanks with Safety Valve on Pressure Regulator Indicates a Change This Printing Use Column 3 for Flux Tanks used on Welding Station t ITEM DESCRIPTION PART NO QTY 1234 6789 Flux Tank Assembly Includes K320 1 Flux Tank Assembly Includes L4695 4 1 XI Flux Tank Assembly Includes L4695 2 1 X 1 G1204 1 Xle
76. 14 gun control cable to the polarized plug built into this small box Complete installation instructions are shipped with the kit K 110 Mechanized March 1979 Sec N3 3 9 K70 FILLET GUIDE Simplifies horizontal fillet welding when using the Mechanized Hand Travel Unit K110 March 1979 Sec N3 3 10 K320 CONTINUOUS FLUX FEEDING TANK ASSEMBLY For LN 9 models N NE and F Standard on S and SE models Complete system including air filter pressure regulator gauge tank and 18 foot flux hose Also includes funnel for filling tank plus lift bail assembly reguired to mount tank and wire feeder to K163 undercarriage The tank can also be used as a free standing assembly October 1991 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N3 3 11 K58 MAGNETIC SEPARATOR Removes magnetic particles from recirculated submerged arc fluxes to reduce porosity and eliminate clogging at the flux cone when making long welds See Sec N4 4 13 March 1979 Sec N3 3 12 K310 SCREEN Vibrated screen available for screening recirculated flux See Sec N4 4 13 February 1980 Sec N3 3 14 K299 WIRE REEL ASSEMBLY For special mounting such as on a robot It includes a reel reel mounting spindle and brake It is designed for 50 and 60 pound coils April 1987 Sec N3 3 15 K376 WIRE REEL ASSEMBLY A mounting stand for 50 and 60 pound coils It is open and does not include a shroud and can be attached to LN 7 LN
77. 33 induj 43 829 65 uns y pae 8 01 11 001 7 p eog jo epis iueuoduoo eouenbes BuuequinN AMED gt JoyoauU0D S gt cs 19661 gS Y 229 pt pnis punou 8520 enuen Dune1odo ees pez vs 10 4ys pue WVS SEH seoinos 1emod ed Jeujo 10 seoinos Jemod 10 uonoeuuo pg uo qUesejd jou esny O N 3 Uld oj pe oeuuoo peddius eq oi jeduinf peog 9 m g uid peddius eq oj precg o d IS S uid oj pejoeuuoo peddius eq oj sedwnf preog 0 JEISOBUY JO 42Eq SE SUONOBUUOD Y d V epejde og jnduj NUN AIL HL ed A S UH 49HOYa30 Sn das ag YYYYYYYYYYYY rry 1111111171 mano 8888288 8898 RS MB af Rue dno opedooog 3 5 Jegunu 0 41691 3 Yad SIOBNAS 199119313 METRIC Bnd jonquo9 peads 169 cee HOUSIU lt ses LN 9H OBSOLETE WIRING DIAGRAM The Lincoln Electric Company Cleveland Ohio 44117 1199 528 015 595 198
78. 42 79 1 X 37 Flux Hose 14 Ft Boom T10642 77 1 ejt JX 38 Hose Clamp Tank End S10888 27 2 40 Lift Bail Assembly M11483 1 XIX Flux Funnel Not lllustrated S11062 1 Air Line Connector Not Illustrated T14390 2 1 1X Q This part is obsolete and no longer available 12 20 2001 P 107 T P 107 T UNDERCARRIAGE K163 Standard with LN 6S LN 6SE LN 8S LN 8SE LN 9S and LN 9SE For optional K163 use parts marked X in Column 1 For LN 6S 6SE 8S 8SE 9S and parts marked X in Column 2 Indicates a Change This Printing ITEM DESCRIPTION PART NO 1234567 89 Undercarriage Includes K163 1 X Undercarriage Includes Standard Eguip 1 X 2 Handle M10469 1 1 XIX 3 Casters S11124 2 XIX 4 Base Platform Type Discontinued L4688 1 4 Base Open Frame L5239 1 6 Wheels S13127 2 7 M10470 1 XX 12 Flux Tank Support S12737 3 X 10 22 97 NOTES P 107 V a P 107 V a MECHANIZED TRAVEL POWER PACK K161 G1429 10 23 81N 05 10 2005 P 107 V b P 107 V b Indicates a Change This Printing Use Parts Marked X in Column 1 for Code 6801 Use Parts Marked X in Column 2 for Code 7627
79. 61 780 781 801 860 882 880 880M and 990 Do not use the magnetic separator with any stainless steel alloy or hardfacing flux except H 535 The magnetic separator removes some of the alloying elements from these fluxes thus changing their characteristics April 1987 Sec N4 4 14 MAKING TEST WELDS See appropriate connection diagram for wire feeder and power source adjustments Adjusting the LN 9 controls a b Set LN 9 electrode polarity switch to same polarity as the electrode lead Connect the Direct Work Lead if it is going to be used Set the Trigger Interlock switch as desired Set the Meter Reading switch to Wire Speed and adjust the Wire Speed rheostat so the meter reads the desired wire feed speed Set the Meter Reading switch to Volts and adjust the Volts rheostat so the meter reads the desired arc voltage IMPORTANT Make certain this setting is within the voltage output range of the power source setting Load the LN 9 with electrode per Sec N4 4 10 through N4 4 12 Operating Instructions Sec N4 4 14 continued g Set up a piece of scrap steel with properly connected work lead Inch the electrode so it extends 1 2 3 4 12 7 19 0 mm beyond the end of the gun for starting h Hold the gun with the electrode lightly touching the work Do not push the wire into the work Press the trigger to start welding i
80. 7 Meter and Pin Assembly Not Shown Order S17747 1 17 Digital Voltmeter P C Board M14490 1 18A Round Head Screw Not Shown 6 32x1 00 2 18B Lock Washer Not Shown T9695 2 2 18C Hex Nut Not Shown 6 32 4 19 Lead Clamp Not Shown LN9 GMA T12563 6 1 Not Shown 19B Self Tapping Screw Not Shown S8025 73 1 19C Washer Not Shown S9262 3 1 LN9 AND LN9 GMA 01 01 2007 LINCOLN Q This part is obsolete and no longer available P 127 H WIRE DRIVE LN9 LN9H LN9F LN9FH 8 EOS P 127 H 1 P 127 H Indicates a Change This Printing For LN9 use parts marked X in Column 1 For LN9F use parts marked X in Column 2 For LNOH use parts marked X in Column 3 For LN9FH use parts marked X in Column 4 ITEM DESCRIPTION PART NO 1 213456789 Wire Drive Motor amp Gear Box Assembly Includes L5743 10 Wire Drive Motor 8 Gear Box Assembly Includes L5743 3 9 1 IX Wire Drive Motor amp Gear Box Assembly Includes L5743 4 1 Wire Drive Motor 8 Gear Box Assembly Includes L5743 6 1 Wire Drive Motor amp Gear Box Assembly Includes L5743 7 0 1 eX Items 2 4C 4B 6 7 8 10 12A 12B 12C 12F 12J 12K 13 1A 6 32x 375 Round Head Screw CF000003 2 1B Lock Washe
81. 7 C to 78 The LN 9 voltage control jumpers must be connected as follows Refer to LN 9 Operating Manual White jumper on voltage board to pin S Blue jumper on voltage board is not connected to any pin Secure loose jumper clear of any possible interference NOTE The trigger interlock feature of the LN 8 models may not reliably function when using pulse welding modes Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Extend lead 21 using 14 or larger insulated wire physically suitable for the installation An 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it separate from the welding work cable connection to work piece For convenience this extended 21 lead should be taped along the welding work cable This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 9 s which have a direct work lead jack Tape up bolted connection Connect the LN 9 control cable ground lead to the frame terminal marked 77 near the power source terminal strip The power source must be properly grounded If using an older automatic control cable with leads 75 76 77 Connect lead 75 to 75 on terminal strip connect lead 76 to 74 on terminal strip connect lead 77 to 73 on terminal strip The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Oper
82. 776 82 1 X 12A Idle Roll Assembly S16666 1 1 X 12B Bearing T13244 1 12C Self Taping Screw S8025 19 1 X 12D Speed Clip T10982 7 1 12E Groove Pin T10580 9 1 X 13A Reed Switch Assembly 12334 43 1 13B Reed Switch Energizer M15173 1 X 14 1 2 13x 75 HHCS CF000020 1 X 15A 1 2 13x1 75 HHCS CF000277 1 15B Lock Washer T9695 8 1 X 15C Plain Washer LN 9 GMA S9262 1 1 X 15C Plain Washer LN 9F GMA S9262 125 1 X 150 1 2 13 HJN CF000054 2 X 16 Conductor Block S17798 1 x 17 Knob T13858 1 X 18A 1 4 20x1 75 HHCS CF000016 2 x 18B Lock Washer E106A 2 2 X 18C Plain Washer S9262 23 2 X 19 Locator Bushing T14031 1 X NSS Not Sold Separately 10 26 2007 LINCOLN P P 127 K 2 P 127 K 2 Indicates a Change This Printing ITEM DESCRIPTION PART NO GTY 1 2 6171819 20 Gear Box Insulation T15049 1 X 21 Gear Box Mounting Plate 17979 1 X 22A 1 4 20x 75 HHCS CF000014 2 X 22B Lock Washer E106A 2 2 X 22C Plain Washer S9262 98 2 X 23 Switch Mounting Housing Assembly S21227 1 X 24A 10 24x1 00 RHS CF000038 1 X 24B Lock Washer E106A 1 1 X 24C Plain Washer S9262 27 1 X 25 Sems Screw T10082 4 1 X 26 Connection Bolt Insulation Not Shown S18169 1 X 27 Hall Effect Switch Not Shown S18160 1 1 X 28 Gas Solenoid amp Support Not Shown M15095 1 1 X LN9 AND LN9 GMA 10 26 2007 LINCOLN P NOTES LN9 AND LN9 GMA LINCOLN P
83. 831 3 1 2 Wire Reel Shaft Assembly M14511 1 2 Spindle Assembly M14935 1 3 Readi Reel Adapter K363 P 1 4 Insulating Washer S10773 52 1 X 5 Insulator Bushing T14816 1 XI 5 Bushing T14844 1 eX 6 Brake Disc Spacer T12967 1 1 7 Plainwasher S9262 14 1 X 8 Lockwasher E106A 15 1 9 Hex Head Screw 1 2 13 x 1 00 1 Xle 9 Hex Head Screw 1 2 13 x 1 75 1 10 Cable Clamp S16819 1 Thread Rolling Screw S9225 8 2 12 Retaining Collar S13871 1 X 13 Readi Reel Decal T13086 44 1 14 Plainwasher S9262 14 1 15 Retaining Collar M14587 1 1 X Optional Not lllustrated 10 Wire Reel Spacer S18221 1 05 09 2002 O This part is obsolete and no longer available 125 125 STAND ASSEMBLY FOR 14 POUND REEL K378 9 10 122013 14 3 4 UU UU UU UUU 24 11 5 7 XP 2 G 1 22 1 28 2002 P 125 0 1 P 125 0 1 Indicates a Change This Printing Use only the parts marked X in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO QTY 1 2 3 4 67819 1 Wire Reel Support Assembly L6831 3 1 X 2 Wire R
84. Argon CO2 blended shielding gas If you are using hotter gases such as Argon Oxygen blends and other processes such as stainless steel MIG arc flaring may occur at start which reguired lowering the start voltage trim as follows a Turn off the control power to the LN 9 at the power source b Remove the screws holding the control section cover in place and swing it open c On the voltage board locate trimmer R41 below R40 next to the 1 8 amp fuse and labeled START d The slot on the START trimmer is marked with a red seal for factory setting To decrease the factory setting turn the slot CCW opposite to the labeled arrow direction NOTE If the start trim is set too low stubbing may occur at start reguiring increasing the START trimmer by turning the slot CW in the direction of the labeled arrow e Re assemble August 1996 Sec N4 4 18 VOLTAGE CONTROL RESPONSE The LN 9 is provided with a pre selected voltage control response Proper setting depends on the power source and process being used Refer to the appropriate power source connection diagram for the proper connection of the jumpers located on the LN 9 Voltage Board and Start Board used on earlier models To change the voltage control response 1 Turn off the control power to the LN 9 at the power source 2 Remove the screws holding the left hand control section cover in place and swing open 3 Position the jumper plugs on the Voltag
85. Corp A29 Special MS Do not use graphite grease 910c Check the motor brushes Replace if they are worn down to 1 4 or less When ordering feed motor brushes give all information from the motor nameplate November 1979 Sec N5 5 3 WIRE REEL ASSEMBLY For 50 and 60 Pound Coils To prolong its life periodically coat the reel shaft with a thin layer of grease No maintenance on the brake assembly is reguired If the brake shoe wears through to metal replace the brake assembly March 1979 Sec N5 5 4 CONTROL BOX Every six months open and inspect the control section The accumulated dirt should be gently blown off all of the electrical components Be sure the air that is being used is dry Check contacts of large plug in relay A spatter resistant shield protects the digital meter This shield must always be installed Should it get broken replace it by removing the two screws securing its frame and install a new clear spatter resistant standard headshield cover plate April 1987 Sec N5 5 5 AUTOMATIC FLUX FEEDING SYSTEM The only maintenance reguired on the flux feeding system is cleaning the water and sludge trap sump Do every six months or whenever air no longer escapes from the coiled tube under the flux tank To clean Turn off the incoming air and release the tank pressure remove the coiled aluminum tubing from the bottom of the filter unit Remove the pinched copper end piece from the end of the aluminum tube
86. D LN9 GMA LINCOLN P P 127 K 1 P 127 K 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO GTY 1 2 67819 1 Drive Motor Asbly LN9 GMA Includes M15078 1 1 X 1 Drive Motor Asbly LN9F GMA Includes M15078 3 1 X 1A Drive Motor NSS 1 X 1B Brush amp Spring Asbly Universal Electric M13274 6 2 X 1B Brush amp Spring Asbly Specialty Motors M14996 F 2 X 1B Brush amp Spring Asbly Stature Electric M15114 1K 2 X 1C Brush Cap Universal Electric M13274 7 2 x 1C Brush Cap Specialty Motors M14907 G 2 x 1C Brush Cap Stature Electric M15114 1L 2 X 1D Plain Washer Not Shown S9262 70 1 X 1E Pinion Gear S17980 1 1 X 1F Roll Pin T9967 33 1 1G Ring Magnet Not Shown 18011 1 X 2 Motor Insulator M13479 4 1 X 3A Bushing T14058 3 X 3B Plain Washer S9262 3 3 X 3C Lock Washer T4291 A 3 X 3D 8 32x1 125 RHS CF000007 3 IX 4 Gear Box L7255 1 1 X 5 Thumb Screw T15046 2 X 6 Drive Screw S8025 19 1 x 7 1 4 20x1 25 HHCS CF000069 1 X 8 Pivot Spacer S10918 7 1 X 9 Plain Washer S9262 103 1 X 10 Quick Release Asbly Old Style Includes M15023 1 10A Latch Knob T13858 1 1 X 10B Quick Release Assembly Current Style M19266 1 1 X 11A Sems Screw T10082 26 1 11B Collar Assembly Below Code 10300 T12341 1 11B Collar Assembly Above Code 10300 21193 1 x 11C Key Below Code 10300 M8
87. E The DC 600 instruction manual IM 306 and the connection diagrams in this manual make reference to DC 600 components The following descriptions and photographs should assist in locating and properly using these components For Codes below 8200 see IM 291 1 Control P C Board Jumper Lead Connections 2 Mode Switch For access to the Control P C board a Turn off all power to the DC 600 b Remove the screws securing the nameplate and control cover c Open the cover and locate the control board which is the P C board on the right side of the control compartment facing the machine Codes Between 8000 and 8045 As shipped these codes had the control P C board jumper leads connected for optimum welding on all processes except solid wire and gas If solid wire and gas is to be used change the jumpers per the following For All Open Arc Processes Except NR 302 and NR 203 Electrodes 1 Set mode switch to CV Innershield 2 White lead on control P C board is connected to Pin M and blue lead to W Can also be used with other processes except that with some Innershield electrodes such as NR 203 and NR 302 erratic arc action may be experienced If a Dual Process Kit K317 or Dual Process Con tactor Kit K318 is used with these codes position the jumpers for the processes to be used according to the information above The only combination not rec commended with the dual process equipment is solid wi
88. ELD POSITION LINCOLN CE DUAL PROCESS KIT sd THE LINCOLN ELECTRIC CO CLEVELAND OHIO U 5 A 5 46391 Closeup of controls for the K317 dual process Note when used with a DC 600 each mode switch should be set in the proper position for the process being used K317 mode switches have no function with any other power source INSTALLATION Refer to the following connection diagrams to connect the Dual Process Kit to the power source and LN 8 or LN 9 wire feeders DC 400 M14549 DC 600 M13751 R3S and SAM M13702 SAF 600 or SA 800 with Solid State M13701 Remote Field Controls PP500 M15081 CV400 M14549 Front of DC 600 Process Kit Turn the power source off On the DC 600 fasten the adapter plate of the Dual Process Kit to the control terminal strip side of the power source using two roof screws and one front panel screw On all other power sources remove the adapter plate from the Kit and fasten Kit to the side of the power source or some convenient location so its control cable can be connected to the power source terminal strip Use control box as a template to locate the four 5 32 4 0 mm diameter holes that must be drilled in the case side Mount unit with the four 10 self tapping screws provided Remove cover from Kit and connect wire feeder control cables to the terminal strips in the Kit Connect the Kit control cable to the power source terminal strip pe
89. KP2123 3 T12057 146 512722 1 16 KP2117 3 KP2130 3 KP2129 3 Cored or Solid 045 052 amp KP545 052 KP2123 2 13343 052 S12722 052 KP2117 2 KP2130 2 KP2129 2 1 0 1 4 mm Solid 045 052 amp KP545 052C KP2123 2 T12057 052 S12722 052 KP2117 2 KP2130 2 KP2129 2 1 0 1 4mm Cored 030 035 amp KP545 035 KP2123 1 13343 035 512722 035 KP2117 1 KP2130 1 KP2129 1 0 8 0 9mm Solid 1 16 amp 1 6mm KP546 1 16A KP2123 3 17729 1 16 817731 116 KP2117 3 KP2130 3 KP2129 3 3 64 amp 1 2mm KP546 3 64A KP2123 2 517729 3 64 S17731 3 64 KP2117 2 KP2130 2 KP2129 2 035 amp 0 9mm KP546 035A KP2123 1 17729 035 817731 035 KP2117 1 KP2130 1 KP2129 1 LN 9 2 Roll Drive OUTGOING CONVERSION INCOMING IDLE ROLL GUIDE OUTGOING WIRE KIT GUIDE DRIVE ROLL ASSEMBLY TUBE GUIDE INSERT 7 64 120 amp KP502 120 KP2123 4 T12057 120 S12722 120 KP2119 1 KP2120 1 2 8 3 0 mm Cored 068 amp 3 32 1 7 2 4 mm KP502 3 32 KP2123 5 T12057 3 32 S12722 3 32 KP2119 2 KP2120 2 Cored amp Solid 1 16 amp 1 6mm Solid KP502 1 16 KP2123 3 S13343 1 16 S12722 1 16 KP2117 3 KP2118 3 1 16 amp 1 6mm Cored KP502 1 16C KP2123 3 T12057 1 16 S12722 1 16 KP2117 3 KP2118 3 045 052 amp KP502 052 KP2123 2 S13343 052 S12722 052 KP2117 2 KP2118 2 1 0 1 4 mm Solid 045 052 amp KP502 052C KP2123 2 T12057 052 S12722 052 KP2117 2 KP2118 2 1 0 1 4mm Cored 030 035 amp KP502 035 KP2123 1 S13343 035 S12722 035 KP2117 1 KP2118 1 0 8 0 9mm Solid
90. LES Sec N6 2 10 1 For K427 045 3 32 request IM 356 2 For K470 and K471 035 5 64 request IM 381 3 For K497 025 045 request IM 434 The Lincoln Electric Company Cleveland Ohio 44117 1199 SEC N6 5 GENERAL TROUBLESHOOTING Maintenance WARNING Have an electrician install and service this equipment Turn the input power off at the fuse box before working on eguipment TRS eje M 00 not touch electrically hot parts can kill Sec N6 6 LN 9 TROUBLESHOOTING To use this guide find the problem in the index below and then see the specific section indicated and follow the instructions See Problem Section A Drive rolls turn but wire will not feed or wire feed A ing is rough or uneven B Variable or hunting arc B C Gun trigger will not feed wire Digital meter is not D lit D Gun trigger will not feed wire Meter is on but E only reads zeros in either the VOLTS or WIRE SPEED setting of the meter switch E Gun trigger will not feed wire Meter is on and F reads SET value of VOLTS or WIRE SPEED F Gun trigger works and arc can be struck Unit then G shuts down while welding or voltage too low to establish arc LN 9 ACTUAL VOLTS meter read ing is low or zero when trigger is closed G Poor arc striking with sticking or blast offs weld C porosity narrow and ropy looking bead or elec trode stubbing into plate while welding
91. Mode switch has no effect ira nj when using SA 800 or SAF eh 12 2 1 600 welders mn ban ls N F Connections shown for LN 9 1 Cite wire feeders For LN 8 wire Spree eared queo feeders connect A to 75 B GR to 76 and to 77 Red N G Electrode polarity on wire feeders set by polarity switch p teeder trode Wire fe feedar 4 ar on power source J To wire feeder wire feeder M13913 Connect the control cable ground lead to the frame terminal marked 777 4 24 81 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Extend lead 21A and 21B using 14 or larger insulated wire physically For 50 Hz Operation suitable for the installation An S16586 remote voltage sensing work lead Disconnect both brown leads is available for this purpose Connect it directly to the work piece keeping from terminal 31B and tape up it electrically separate from the welding work lead circuit and connection each lead Untape both red For convenience these extended 21A and 21B leads should be taped leads and connect to 31B to the welding work lead Each lead must be connected directly to the work and leads must not be connected together Sec N2 3 3 0 K318 DUAL PROCESS CONTACTOR KIT ABOVE CODE 8020 SAF 600 AND SA 800 CONNECTION TO TWO LN 8 S OR TWO LN 9 s FOR OPPOSITE POLARITY OPERATION Obsolete gom mJ
92. N 9 stops welding follow this procedure a Move the LN 9 voltage set point 2 volts lower than the desired procedure and make a test weld 1 If the LN 9 still shuts down go to Step b below 2 If the LN 9 keeps welding change the R3S triangle setting to the next higher voltage and reset the LN 9 set point to the desired procedure R3S is now set properly unless there is a significant change in input voltage Skip Step b b Move the LN 9 voltage set point 2 volts higher than the desired procedure and make a test weld 910c Maintenance 1 If the LN 9 now keeps welding change the R3S triangle setting to the next lower voltage and reset the LN 9 set point to the desired procedure The R3S is now set properly unless there is a significant change in input voltage 2 If the LN 9 still shuts down refer to the paragraph below and the other possible causes previously listed In some cases it is also possible to hold the ACTUAL button pressed while starting the arc Before the LN 9 shuts down the actual arc voltage can be read on the digital meter Comparing this reading to the SET reading will tell what change in the range controls of the power source are reguired so it can supply the desired voltage Should the meter read zero check LN 9 sensing leads 21 and 67 connections Should the meter read a minus voltage the polarity connections or settings at the LN 9 or power source are wrong This same general
93. N TO TWO LN 8 s OR TWO LN 9 s FOR SAME POLARITY OPERATION 21A21B Welder control cable Welding lead stud on back of contactor kit a ou N A 3 nanom 32 Electrode Wire tesder cables control le NA Wire leeder control cable 2 2 A wire teader Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Sec N2 3 3 U K318 DUAL PROCESS CONTACTOR KIT Extend lead 21A and 21B using 14 or larger insulated wire physically suitable for the installation An 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience these extended 21A and 21B leads should be taped to the welding work lead Each lead must be connected directly to the work and leads must not be connected together To wiro feeder For 50 Hz Operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B N F N G Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Bolt and tape connections
94. O d WN SION METRIC ne epedese P JESS 10 Se suonoeuuon gwn aY DO YU 479 49120uuo5 eppeidooog 2242220248 YYY 1 51 3 Wad STOBWAS 1VOIHLO3T3 di Wd nenu 888 Du Gene NB 005 indino 8589 2799895885 aaa 2 S phle 9 Ajeoneuben Fran YESI ao TEISCOUY U ionuoz peads ra ies gt 590 779 ee LE9 29 29 5 YOUMS r lt jeriov ies lt ses 134 W H h xs Gwr ves es yesoouu le juo Ses 015 SSS SZS 22 ZES p og 2 4 g 19 6 gt 9 vee acc e 5 gt 169 7142 004 oos s wv Jedump eng gi 129 o jo m 9145 rzs 8 2 zis ros ers zos lt r vig d 8 gt gt 4 gs jee WN E gt t scs 829 RAIL 8 je os 40dwnp 7 9 ze ors peog 9 d 55 an ozs SN 85 15 3 dWV 8 1 l peog dl uos uonoeiig Auejo 49 Yt peog jno doup Y Jope euondo qui peDBnid me md S Jojpeuuoo
95. OR KIT ne WE CD ONN USA Closeup of controls for the K318 dual process contactor kit NOTE when used with a DC 600 each mode switch should be set in the proper position for the process being used K318 mode switches have no function with any other power source OPERATION For DC 600 set the mode switch on the front of the power source to CV Innershield Set the mode switches on the Assembly and Installation Sec N3 5 2 continued kit to the position reguired by the process used on the wire feeder On all other power sources the mode switches have no effect Check that transfer switch on the dual process contactor kit is in the proper position When wire feeders are connected for opposite polarity operation wire feeder A will be negative polarity and B will be positive polarity Codes Above 8020 Before welding actuate gun trigger once to interlock contactor and set procedure Subseguent welding with the same gun can be done in a normal manner If the trigger is not operated once when changing feeders the first weld start may be poor if the voltage setting of the two feeders is far apart The Lincoln Electric Company Cleveland Ohio 44117 1199 To set procedures weld with A wire feeder and set procedure with its control dials Then weld with B wire feeder and set the procedure with its control dials With the LN 9 it is not necessary to weld Each unit
96. PART NO GTY 1 2 7819 1A Self Tapping Screw S8025 14 3 X 1B Trigger P C Board M13861 3 1 1B Trigger P C Board Above Code 8000 GMA L9928 1 1C Plastic Expansion Nut 14020 1 3 X 1D P C Board Insulation Below Code 8000 T14274 1 X 1D P C Board Insulation Above Code 8000 S16609 1 X 2 Reed Switch Assembly S12334 29 1 X 3 Lead Clamp T12563 7 2 X 4 8 32x 50 Br RHS CF000102 2 X 5A Control P C Board LN9 amp 9H Only L6019 1 X 5A Control P C Board LN9 GMA Only Below Code 10352 L7253 1 X Control P C Board LN9 GMA Only Above Code 10352 L10068 1 5B P C Board Insulation LN9 amp 9H Only S16365 1 X 5B P C Board Insulation LN9 GMA Only S16365 1 1 X 5C Plastic Expansion Nut S14020 1 2 x 5D Self Tapping Screw S8025 14 1 X 6 Instrument Mounting Panel Below Code 8000 M13580 o 1 X 6 Instrument Mounting Panel Above Code 8000 M13580 1 1 7A Power P C Board LN9 amp 9H Only L6043 1 7A Power P C Board P M GMA L7265 1 X 7B P C Board Insulation LN9 amp 9H Only S16363 1 X 7B P C Board Insulation LN9 GMA Codes 9135 9160 S18006 1 X 9960 9843 10320 10326 10353 7B P C Board Insulation LN9 GMA S18006 1 1 X 7C Plastic Expansion Nut 14020 1 5 X 7D Self Tapping Screw S8025 14 5 X 8A 6 32x 625 RHS CF000043 2 X 8B Lock Washer E106A 13 4 X 8C 6 32 HN CF000005 4 X 9 Lead Clamp T13496 2
97. Sec N4 4 7 Set Actual Push BUHON ne Wy Sec N4 4 8 Electrode Hot Cold Switch LN 9F only iii Sec N4 4 9 Wire Reel Loading 60 and 50 Pound Reels 0 ccccccscsecssssecsccesescecsecesvecsescssacsesevasacsvacessessuavssscsarsesessseeses Sec N4 4 10 Wire Reel Loading Readi Reels and 10 to 30 Pound Spools uuuuu ALLAI LU LS Sec N4 4 11 Threading Electrode into Machine Sec N4 4 12 1 When Not Using Extension Assembly Models N and S 2 When Using the Extension Assembly Models NE and SE Lodding the Tank e nece GWYW WB s OR AW WN AR Sec N4 4 13 Making Fest Welds un y fn RD GG SW GR Sec 4 4 14 Adjusting the LN 9 Controls Making Submerged Arc Welds siennes Sec N4 4 15 Procedure at End of eie cha FWYD Sec N4 4 16 Starting Characteristics n Sec N4 4 17 Volt ge Control ResbOIlSe estafas COF ten Sec 4 4 18 Security of Weld Procedure Settings issues Sec N4 4 19 Sec N5 General Maintenance Drive Rolls and Guide Tubes anennrennennes Sec N5 5 1 Wire Drive Motor and Gear BOX inner YUA CDC DL ADC FARA Sec N5 5 2 Wire Reel Assembly 50 and 60 Pound Coils ALLA LLALL Sec N5 5 3 Control E Sec N5 5 4 Automatic Flux Feeding System c cccccsscssessessscccsssssesesescsesesscsesssessvsessssvassserssssvssssssesssavecsesesevsvsasacansesenace
98. Tank LN9S and LN9SE P 107 S Undercarriage K163 Standard on LN 9S and LN 9SE P 107 T Stand Assembly for Readi Reel K377 P 125 N Stand Assembly for 14 Pound Reel K378 125 Miscellaneous Options Mechanized Travel Power Pack K161 P 107 V 600 Amp Contactor Kit P 107 W 2 Mechanized Hand Travel Unit K110 P 107 X Gear Box for Spr P 107 Y Solid State Remote Field Control K224 P 114 H See IM278 Burnback Kit Except GMA Models Order K202 Burnback Kit GMA Models Order K419 10 thru 60 pound Spindle Kit 2 00 Dia Order K162H Swivel Type Mounting Platform Order K178 un adu Te el ROSE rear e ce bd IM235 P 57 C D E Dual Process Kit Ka 7 Ab x cele ees utet CERE me PE AN P 127 P Dual Process Contactor K318 P 127 U Dual Procedure pret cepere ERE E DAC UE Ya P 127 R Gas Solenoid Valve Kit Below Code 9100 Only Not Req d on GMA Models Order K437 Gas
99. UC ES DO FABRICANTE PARA ESTE EOUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR lt TL TRHOREREK HT FSU TR RE A TD ER A OM ARRAN MAU MRAM REA RS IO R FR DRE e HE Sixes HA GEAR PES EF N all yll wl llai Cy al gll og giat Llai pls ma s il LINCOLN P World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
100. Wniov i3s 03345 51 L 7198 Dimension Print LN 9F WIRING DIAGRAM The Lincoln Electric Company Cleveland Ohio 44117 1199 0334 38IM ajge9 indy 9jge9 unt 808 Y 625 3 9 gt 196 6 5 gc Y 229 pnis eseg epoo W98 P I 11 Nieuiaoejdau 10 juawyedeg 86171 eui O ei si ou sjaued eunsopoua 24 JO uo au episul pyeog jo epis iueuoduoo s apoo 4ejnojued 10 eouanbeg BuuequinN AIAEO wesBejp syjoeds oui jyenuew si Aq je 10 91g4n228 jou 1 eae a 13434 10 61 144 LON TES ri 199 ees vs JO AVS NVS SEH seoinos Jemog ed 10 5691005 8dA 9 Q uonoeuuoo spse0g 9 d uo jueseud JON peioeuuoosip si uondo eu 4edunf eu pie0g lt g eui o peioeuuoo s pJeog Jay 8mod peuondo eu si Dnjd O N 4 uid a peioeuuoo paddiys eg o Jedwinf peog O d Jonuoo m 8 UId oj peioeuuoo peddius eq enjg peog eBeioA gS penoeuuoo eq pigog
101. any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service reguirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Eguipment For Damage Immediately When this eguipment is shipped title passes to the purchaser upon receipt by the carrier Conseguently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your eguipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number
102. arning 113470 1 4 Door 114882 1 8 32x 50 Round Head Screw CF000033 1 XIX 5B Plain Washer Not Shown S9262 3 1 5C Lock Washer Not Shown T4291 A 1 5D 8 32 Hex Nut CF000042 1 X X 5E Lead Clamp Not Shown T12563 7 1 6A Voltage P C Board Code 7949 Only L6041 1 6A Voltage Board Code 7949 A to 9000 L6084 1 6A Voltage P C Board Code 9000 to 9100 L6084 2 1 6A Voltage Board Above Code 9100 L6084 1 XIX 6B P C Board Insulation S16364 1 7 Security Panel S16275 1 8 Knob T10491 2 9 Potentiometer amp Plug Assembly includes Not Shown S14165 173 1 9A Potentiometer S16296 1 2 XX 9B Felt Washer T14034 2 XX 9C Plain Washer S9262 76 2 9D Insulating Tube T7028 241 2 10 Dial Plate S16277 1 11 Lock Tab T10045 40 1 12 Self Tapping Screw S8025 70 4 13 Self Tapping Screw S8025 60 1 Note When ordering new printed circuit boards indicate the dash number of the Old board that is to be replaced This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters The dash number brackets have purposely been left blank so as to eliminate errors confusion and updates LN9 AND LN9 GMA LINCOLN P 10 04 2005 P 127 D P 127 D HINGED DOOR ASSEMBLY LN9 amp LN9 GMA 2 Roll am
103. as no effect when wire fonder feeder using the lower wire foeder position a Dual process kit HAE feeder to power source connection diagram Refer to appropriate wire BE cu e g olol 38 llo 288 o o s oto 4 sr MH 0325 32 oats 358 31 Wire teeder control cable To A wire feeder Wire feeder control cable B wire feeder Wire feeder control cable N B N F N G N H using SA 800 or SAF 600 welders Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications Bolt and tape connections Tape up leads Connections shown for LN 9 wire feeders For LN 8 wire feeders connect A to 75 B to 76 and to 77 Electrode polarity on wire feeders set by polarity switch on power source Connect the control cable ground lead to the frame terminal marked 7 7 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded Use 14 or larger wire physically suitable for the installation and connect it directly to the work piece keeping it separate from the welding work lead circuit and connection M13701 4 24 81 N A Mode switch has no effect when N B N C N D N E N F using R3S or SAM welders Welding cable
104. asoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH 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 recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 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 1 h To avoid scalding do not remove the N FOR ENGINE remove th powered eguipment A i y ae pressure cap when the engine is 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 23 areas or vent the engine exhaust fumes AR outdoors ELECTRIC AND SR MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flam
105. ating Manual White jumper on voltage board to Pin 5 Blue jumper on voltage board later units only or on start board earlier units to Pin B Set the DC 1000 controls as follows Set the control switch to Output Control Remote For Submerged Arc Processes set the mode switch to C V Submerged Arc For Open Arc Processes set the mode switch to C V Innershield Alternative 500 Amp positive terminal connection provided on DC 1000 models above code 9500 only Assembly and Installation Sec N2 3 3 L K317 DUAL PROCESS KIT SAF 600 AND SA 800 CONNECTION TO LN 8 OR LN 9 Obsolete Elacirode polarity switches on power source and field convo must be set on same polarity Power must be off when changing polarity 1 ss pee Connect to desired electrode terminal Auto aN Ewe d N Tom fi get Sec N2 3 3 M 7 Dual process kit wire feeder When either or both wire ara other than LN 9 the voltage process must be connected m K317 DUAL PROCESS KIT R3S AND SAM CONNECTION TO LN 8 OR LN 9 source Connect to same numbered terminal 1 on power source terminal strip Tape up these leads To negative output To positive output stud on power source stud on power source nc N B To work Welder control cable The Lincoln Electric Company Cleveland Ohio 44117 1199 N A Mode switch h
106. ating Washer T4479 A 2 9D Plain Washer S9262 27 1 9E Lock Washer E106A 1 1 QF 10 24 Hex Nut CF000010 1 10A Thread Forming Screw 9225 4 10B Lock Washer T9695 1 1 11A 3 8 16x 875 Hex Head Cap Screw CF000070 1 XIX 11B Lock Washer E106A 16 1 11C Plain Washer S9262 120 2 12 Self Tapping Screw S8025 4 2 13 Switch Box Assembly includes Below Code 8000 S16270 9 1 13 Switch Box Assembly includes Above Code 8000 S16270 1 1 XIX Except LN9 GMA 2 amp 4 Roll 13 Switch Box Assembly includes LN9 GMA 2 amp 4 S16270 2 1 Roll Drive 13A Polarity Switch T13111 1 13B Direction Switch Above Code 8000 T14535 1 Except LN9 GMA 13B Direction Switch LN9 GMA T10800 7 1 13C Trigger Interlock Switch Below Code 8000 T10800 4 1 Not Shown 14 Switch Box Not Shown M13576 1 15 Plug Button LN9 4 Roll Only T10397 4 2 X 16A 3 8 16x 625 Hex Head Cap Screw CF000018 2 16B Lock Washer E106A 16 2 Resistance Coil Below Code 9100 T14104 1 LN9 AND LN9 GMA 01 01 2007 Q This part is obsolete and no longer available P 127 F P 127 F CONTROL PANEL INSTRUMENT ASSEMBLY LN9 amp LN9 GMA 2 Roll amp 4 Roll ge Not S ig y Wo LN9 AND LN9 GMA LINCOLN P P 127 F 1 P 127 F 1 Indicates a Change This Printing ITEM DESCRIPTION
107. ator amp Switch Assembly T14751 1 1 X 2B Lock Washer T9695 16 1 X 2C Hex Nut T10940 11 1 X 3 Meter Shield Frame M13572 1 X 4 Sems Screw T10082 27 2 X 5 Meter Printed Circuit Board LN9 Only L6685 1 5 Meter Printed Circuit Board LN9H Only L6686 1 5 Meter Printed Circuit Board LN9 Metric Only L6687 1 X 5 Meter Printed Circuit Board LN9H Metric amp L6688 1 X LN9 GMA Onl 6 Nameplate M13582 1 6 Nameplate LN9 LN 9H Metric 8 LN9 GMA Onl M13582 1 1 Switch LN9 Only T13111 1 7A Switch LN9H Only T13381 2 1 7A Switch LN9 LN9H amp LN9 GMA Only S16670 5 1 7B Washer T14457 1 1 7 Plain Washer S9262 76 1 7D Knob T13639 1 8 Meter Panel Assembly T14248 1 8 Meter Panel Assembl T14248 1 1 9A Shock Mounting T13003 4 9B Sems Screw T10082 27 4 9C Lock Washer T9695 3 4 9D Hex Nut 78 32 4 10A Round Head Screw 6 32x 50 2 10B Lock Washer T9695 2 2 10C Hex Nut 6 32 4 11A Insulation S16635 1 X 11B Self Tapping Screw S8025 60 2 12 Insulation 714468 1 X 13 Spatter Shield 17016 1 X 14 P C Board Spacer M14537 1 15 Bezel Assembl 17414 1 x 16 Meter Shield Standard Clear Welding Lens T14771 1 16 Filter Lens T14807 1 1 17 Meter and Printed Circuit Board Assembly Not Shown M13650 9 1 1
108. auxiliary equipment Route the leads to the terminals marked 32A and 7 which come through the rectangular hole in the control section sheet metal near the wire feed motor LN 9F or LN 9FH Models Install terminals for 6 screws to the leads from the auxiliary equipment Route the leads to the terminals 32A and 7 on the terminal strip on the inside bottom of the control box 910c Assembly and Installation Auxiliary Equipment Contacts MM Amm LI LN 9 and LN 9H Obsolete Auxiliary Terminal Strip LN 9F and LN 9FH Obsolete Sec N3 3 7 K62 SGUIRTMOBILE The Squirtmobile is a self propelled trackless carriage that carries the K114 submerged arc gun on long welds for automatic welder economy without high fixture costs To use the LN 9S or LN 9SE with the Squirtmobile install a K161 Power Pack Kit per Sec N3 3 8 January 1989 K62 Squirtmobile Assembly and Installation Sec N3 3 8 K161 MECHANIZED TRAVEL POWER PACK Not designed for use with the LN 9F or 9FH Obsolete units The K161 power pack supplies the power needed by the K110 mechanized hand travel unit or Sguirtmobile when used with the K114 submerged arc welding gun K 161 Power Pack Connect the leads of the power kit box the one with the handle to the power source Extend the control cable to the wire feed unit Mount the small box at the end of the cable to the front of the wire feed unit Connect the K1
109. connect a Remove the three 3 8 screws from the back of the wire drive unit b Place the wire drive unit in position against the wire reel mounting bracket Replace and tighten the screws The long screw with plain washer goes into the top hole April 1987 910c Assembly and Installation Assembly and Installation Sec N2 2 6 INPUT CABLE CONNECTIONS TO LN 9 1 Models LN 9N LN 9HN Obsolete and LN 9S The input cable consists of an electrode cable and multi conductor control cable The control cable has a polarized plug on the wire feeder end To install a Connect the polarized plug of the control cable to the mating connector on the back of the wire feeder b Remove the screws holding the cable clamp located near the rear of the wire reel base Put the control cable and the electrode cable under the clamp and install the screws On cables with more than one electrode cable leave the junction between the two or more cables and the single 4 0 stub behind the clamp so only the single electrode lead is under the clamp c Pass the single electrode cable through the holes provided in the back corner of the control section and fasten it to the copper strap on the wire drive unit Models LN 9NE and LN 9SE The hand crank assembly mounted on the wire reel base is set up to feed all wire sizes a Position the Extension Assembly cable so the Amphenol plug with the threads on its O D can be attached to the Amp
110. ctrode Wire feeder control control cable cable A N G To A wire feeder electrode negative electrode positive N A A Connect the control cable ground lead to the frame terminal marked 777 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Extend lead 21A and 21B using 14 or larger insulated wire physically suitable for the installation An 516586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience these extended 421A and 21B lead should be taped to the welding work lead Each lead must be connected directly to the work and leads must not be connected together To wire leeder M13918 11 2 79 For 50 Hz Operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B proper capacity for the current and duty cycle of immediate and future applications Bolt and tape connections Put transfer switch in opposite polarity on feeders position Place mode switch on power source to CV Innershield and place each mode switch on dual process control in the position required by process used with wire feeder To make A feeder positive polarity and feeder negative polarity reverse electrode cabl
111. d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s a deux machines a souder parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le cable lectrode autour de n importe quelle partie du corps PRECAUTIONS DE SURETE POUR soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer d
112. d rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this eguipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY KT WELDING and CUTTING lt SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the eguipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not
113. d with the platform October 1991 LN 9N or 9HN Obsolete with K162 H Spool Spindle Sec N3 3 2 K162 H 10 to 60 POUND READI REEL SPOOL SPINDLE To mount the spindle kit remove the shaft for the standard 50 60 pound wire reel from the mounting framework Install the spindle per the instructions shipped with the kit When used with Readi Reels an appropriate Readi Reel Adapter is reguired A K468 Adapter is reguired when using 8 200 mm diameter spools and a K435 Adapter for 14 Ib Innershield Coils Adjust the brake tension screw on the spindle as needed October 1991 910c Sec N3 3 3 K163 UNDERCARRIAGE For all LN 9 Wire Reel Stand Combinations Wheels handle and hardware are shipped with the undercarriage Mount the casters at the front and wheels to the rear of the platform Be sure the round rear axle is to the rear of the mounting bolts that hold the U shaped axle member to the frame Bolt the handle to the front of the platform so it can be tilted back and wheeled like a two wheeled truck Holes for installing the wire reel support are provided in the platform October 1991 Assembly and Installation Sec N3 3 4 File as Sec K2 5 7 in IM 274 K202 Burnback Kit For all models of LN 9 This kit is useful to help prevent the electrode from sticking in the crater or ending with too much stickout at the end of the weld in two types of welding applications 1 Welding with small diameter 03
114. ded to set and monitor the welding procedure The arc voltage is displayed in volts and the wire feed speed is displayed on Metric LN 9 models in either inches minute or meters minute December 1982 Sec N4 4 7 METER READING SWITCH VOLTS AND WIRE SPEED CONTROLS The switch is located to the right of the digital meter on LN 9 and LN 9H obsolete models and to the left of the procedure control knobs on LN 9F and LN 9FH obsolete models LN 9 models below Code 8600 use a two position toggle switch When set to Volts the meter reads the arc voltage setting as adjusted by the Volts control on the LN 9 When set to Wire Speed the meter reads the wire feed speed in in min as adjusted by the Wire Speed control on the LN 9 Metric LN 9 models above Code 8600 use a four position rotary selector switch When set to the Volts position the meter reads the arc voltage setting as adjusted by the Volts control The three Wire Speed positions include an English position for meter readings in inches minute and LO and HI range Metric positions for meter readings in meters minute The wire feed speed setting is adjusted by the Wire Speed control on the LN 9 When using Metric meter readings set the switch to LO for more precise meter readings up to 9 99 m min 393 in min For higher wire feed speeds the LO position will result in an
115. ds When welding pushing the gun into the fillet The operator does not have apply slight pressure down and forward on the gun to constantly control the drag of the flux cone against the This insures contact of guide wheels and the drive vertical plate nor carefully watch the angle of the gun wheel with the plates 1 Installation Sguirtgun K 114 Fit the vertical plate roller guide directly on the gun nozzle Clamp the rear wheel to the gun as shown in the sketches Use of the rear wheel reguires a riding surface under the handle 7 to 11 inches 180 to 280 mm from the vertical plate Exact location of the rear wheel is not critical However the greater distance provides better stability and ease of operation Even if the horizontal surface is not available using the roller guide without the rear wheel still aids in making fillet welds If the nozzle extension used with long stickout procedures is installed replace item 15 with the long guide roll arm item 16 This is shipped loose with the fillet guide kit 2 Operation After the Fillet Guide is installed with the rear wheel placed as reguired for the application see Installation proceed as follows a Position the travel unit so the nozzle flux cone is at the right height to deposit enough flux to cover the arc b Inch the electrode out so the point will just miss touching the plate when the gun is held in the proper position for welding The electrode end s
116. e welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing eguipment In some cases it may be necessary to remove safety guards to perform reguired maintenance Remove guards only when necessary and replace them when the maintenance reguiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan e Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running AY 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 5 Exposure to EMF fields in welding may have other health effects which are now not known All welders should u
117. e Board and the Start Board used on earlier models per the appropriate power source connection diagram 4 Reassemble In an LN 9F and 9FH obsolete the Voltage Board is mounted on the right hand wall of the control box This places pins S and F behind the upper molex plug and out of sight of the viewer When moving this jumper be sure to remember that S is the top pin and F is the bottom pin January 1989 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N4 4 19 SECURITY OF WELD PROCEDURE SETTINGS There are two means provided to prevent or limit unauthorized readjustment of the LN 9 voltage and wire feed speed controls once set to the desired procedure Once the procedure is set the security panel of the LN 9 can be locked to prevent access to the control knobs The control range of the procedure control knobs can be limited to either about 390 or about 1596 of the full range control by installing a knob rotation stop screw to either or both of the control knobs This stop screw is installed in the following manner 1 Turn off the input power to the LN 9 2 Loosen the knob set screw and remove the control knob and the felt seal located behind the knob 3 Remove the control potentiometer locknut and fiber spacer then open the control panel and remove the potentiometer from the panel 4 Install a 1 2 long pan or round head 4 metal screw into the 10 dia hole located 4
118. e the locking collar and remove the outside Readi Reel adapter arm Engage the inside Readi Reel adapter arm in the brake driving pin and rotate the spindle until the inside adapter arm is in the vertical position Set the Readi Reel on the adapter arm The Readi Reel must be installed so that it will rotate in a clock wise direction when feeding wire is dereeled from the bottom of the coil The outside adapter arm is then placed on the spindle at an angle of 90 from Operating Instructions Sec N4 4 11 continued the inside adapter and the locking collar installed Tighten the locking collar securely BRAKE DRIVING FIN BRAKE TENSION SCREW REEL SPACER To mount 15 to 30 Ib spools remove the locking collar and the Readi Reel adapters from the 2 inch dia spindle Place the spool in the spindle making certain the brake driving Pin enters one of the holes in the back side of the spool Be certain the wire comes off the reel in clock wise direction Replace and tighten the locking collar When 8 O D spools are used place the K468 spindle adapter on the spindle between the brake driving pin and the spool To feed the electrode turn the Readi Reel or spool until the free end of the electrode is accessible While tightly holding the electrode cut off the bent end Straighten the first six inches and cut off the first inch Insert the free end through the incoming guide tube Press the gun trigger and push the elect
119. e ventilation or exhaust to remove fumes from breathing zone FUMES AND GASES can be dangerous Keep flammable material away Do not weld on containers that have held combustibles WELDING SPARKS can cause fire or explosion Wear eye ear and body protection ARC RAYS can burn IMPORTANT SAFETY NOTE This wire feeder provides COLD electrode when gun trigger is released This feature and DC Constant Voltage output provide an added margin of safety when welding must be performed under electrically hazardous conditions such as damp locations while wearing wet clothing on metal structures or in cramped positions sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground Sec 4 4 1 WIRE REEL BRAKE 50 60 Pound Reel Mounting The mount for standard 50 and 60 pound electrode coils includes a two position brake assembly Generally the brake should be at the inner position nearest to the wire reel 910c shaft for wire feed speeds below 400 in min 10 m min It should be at the outer position for faster wire speeds To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit October 1991 Sec N4 4 2 DRIVE ROLL PRESSURE See Sec N2 2 2 N2 2 4 Setting the Drive R
120. e with the wire feed unit Install these parts per the following instructions 1 Loosen idle roll spring pressure screw 1 2 Remove clamping collar 2 from the drive shaft 3 Install drive roll 3 with the key and replace clamping collar 2 Tighten screw 4 4 Remove the idle roll shaft screw 5 install idle roll 6 Replace screw and tighten 5 Remove the large ingoing guide 7 from rear brass block by loosening screw 10 6 Loosen the ingoing guide tube clamping screw 8 Install the guide tube 9 which is stenciled in through the rear brass block Tighten the locking screw 7 Replace the large ingoing guide 7 tube into the rear brass block Tighten the locking screw 10 8 Install the outgoing guide tube 11 with its plastic insert through the front brass block Tighten the locking screw 12 so the dog point goes into the groove in the O D of the guide tube NOTE The Aluminum Wire Drive Roll Kits have one piece drive rolls and idle rolls with a large chamfer on one side instead of gear teeth This large chamfer side must face the gearbox when installed The side with the smaller chamfer and wire size stencil must be installed facing out March 1979 Sec N2 2 2 SETTING THE DRIVE ROLL SPRING PRESSURE TWO ROLL WIRE DRIVE SYSTEM NOTE The drive rolls and guide tubes are stamped with the wire size for which they are designed If a wire size other than that stamped on the components is to be
121. eel Housing Includes S17069 2 1 X Housing M11940 1 X Wire Sheath T14800 1 X Wire Sheath Insulating Block S17068 1 X Support Washer S15094 1 X 3 Axle S13954 1 X 4 Round Head Screw 10 24 x 875 4 X Lockwasher E106A 1 4 X 5_ Washer T13984 1 X 6 Axle Housing S13953 1 X 7 Wire Reel Cover Back M11574 2 2 X 8 Self Tapping Screw S8025 22 4 X 9 Spring T11862 8 1 X 10 Plainwasher S9262 45 1 X 11 Insulating Washer S10773 49 1 X 12 Hex Head Screw 5 16 18 x 75 1 X Lockwasher E106A 3 1 X Plainwasher S9262 61 1 X 13 Wire Reel Cover Front M11574 2 1 X 14 Axle Nut S13956 1 X 20 Housing Cover M11578 1 X Decal S118932 1 X 21 Cover Retaining Strap Assembly S15891 1 X 22 Cable Clamp S16819 1 X Thread Cutting Screw S9225 8 2 X 23 Coil Support Disc S17060 1 X 24 Thread Cutting Screw S9225 30 2 X 05 09 2002 O This part is obsolete and no longer available NOTES LN 9 AND LN 9 GMA LINCOLN 5 P 107 M INPUT CABLE AND EXTENSION CABLE ASSEMBLIES P 107 M Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 67 89 LN 6 Power Input Cable Assembly Includes K164 1 Control Cable Assembly Includes L4700 B 0 1 Amphenol Connector Female S12020 11 1 Amphenol Connector Male S12020 12 1 Amphenol Connector Clamp S12024 2 2 Electrode Cable Assembly L4700 C 1 LN 8 amp LN 9 Power Input Assembly Includes K196 1 Control Cable Assembl
122. efer to operating manual a Mode switch in wrong position on Dual Process Contactor Kit or on welder Place in correct position b Defective K317 relay replace relay a Improper connection on power source terminals N P and S Refer to connection diagram to connect properly November 1990 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N3 5 2 File as Sec K 2 5 19 IM 274 A K318 DUAL PROCESS CONTACTOR KIT With Polarity Change The dual process contactor kit is a control box transfer device that permits connection of two wire feeders to a single power source and enables each wire feeder to weld at a different procedure and polarity without changing any dials or switches Simply actuating the gun trigger of the desired wire feeder turns the unit on selects the polarity and sets the complete procedure including power source output level When used with a DC 600 the wire feeders can also be set for different modes CV Innershield or CV Submerged Arc The kit can also be connected to operate with the same polarity on each wire feeder The kit is rated 600 amperes at 100 duty cycle Maximum versatility is obtained when the kit is used with a DC 600 power source The following chart shows the advantage that a DC 600 has over other welders PowerSource ange oc4o o o Fw vw Solid State Remote Control S CV 400 The output range is limited by the voltage c
123. eft hand Apply a downward pressure to the idler roll pressure arm with the right hand Maintain this pressure and start cranking the wire through the system Keep the conductor cable as straight as possible during the loading operation This will make it much easier to crank the wire through Crank until the wire touches the drive rolls operate the gun trigger and feed the wire through the cable and gun assembly WARNING The electrode is hot to ground while inching with the gun trigger NOTE On Codes above 7980 the Trigger Interlock and Hot Cold Wire Feed Switch should be in the center position In this position the wire may be fed electrically cold Push the plastic of the hand crank to the in position and shift the ingoing guide tube to the forward position The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions Sec N4 4 12 continued The proper position for the hand crank arm when it is not being used is shown in the sketch below HAND The purpose of the separator is to remove magnetic materials such as mill scale and any other extraneous magnetic materials which may have been recovered along with the flux to be processed It is important to remove these magnetic particles from the flux which is to be reused in the continuous flux feeding system If the magnetic material is not removed it will gather around the nozzle of the gun and impede or shut off the
124. el No Shroud use Column 3 For lightweight LN 6NE 6SE 8NE 9NE and 9SE use Column 4 For LN 22 use Column 5 For K445 use Column 6 ITEM DESCRIPTION PART NO QTY 1234567 89 LN 6 LN 7 LN 8 8 LN 9 Wire Reel Support Assembly Includes L4699 2 1 LN 7 Wire Reel Support Assembly Includes L4959 2 1 LN 7 Wire Reel Support Assembly Includes L4959 3 1 je X 1 Wire Reel L4604 1 XIX 1 Wire Reel 18179 1 X 2 Wire Reel Housing For LN 7 K376 Reel See Note 1 513858 1 3 Reel Support L4680 1 4 Plain Washer S9262 23 6 5 Lock Washer E106A 2 3 6 1 4 20 CF000017 3 7 1 4 20 x 1 50 HHCS CF000141 3 8 Insulating Washer S10773 41 12 9 Insulating Tube T7028 90 1 10 Reel Mounting Shaft Assembly See P 107 P 1 10 Reel Mounting Shaft Assembly Order K162 H 1 X 11 Cable Clamp S16819 1 12 Thread Cutting Screw S9225 8 2 13 Insulating Tube T7028 180 2 Optional Door Assembly Includes M11514 Note 1 1 XIX X Door and Hinge Welded Assembly L4692 1 Catch T12652 1 X X Sealing Panel S14049 1 Sealing Panel Mounting Plate S14067 2 LN XNE amp LN XSE Fully Wire Reel Support Assembly Includes all Above plus L4745 0 1 X X LN
125. elding cables must be of proper capacity for the current and duty cycle of immediate and future applications Connection shown for positive polarity For negative polarity reverse electrode and work cables connected to power source output studs Connect the control cable ground lead to the frame terminal marked 777 near the power source terminal strip The power source must be properly grounded Use 14 or larger wire physically suitable for the installation and connect it directly to the work piece keeping it separate from the welding work lead circuit and connection N F Bolt and tape connection N G Tape up separately N B N C N D N E Wire feeder control cable Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 3 3 P K318 DUAL PROCESS CONTACTOR KIT ABOVE CODE 8020 SAF 600 AND SA 800 CONNECTION TO TWO LN 8 s OR TWO LN 9 s FOR SAME POLARITY OPERATION Obsolete N A Welding cables must be of Welding lead contactor Ki proper capacity for the current Se eee n and duty cycle of immediate pr o 279 applications ax source must be when changing polarity NC 5 g t an pe connections En INTR 424123 H 4 re N C Tape up leads 53 N D Put transfer switch in same Go DNE n polarity on feeders position 244 8 N E
126. er Connector Not Used On LN9F GMA 12021 18 1 X Input Connector 12021 12 1 Output Connector LN9F amp 9FH 12021 10 1 Output Connector LN9F GMA 12021 37 1 X Note When ordering new printed circuit boards indicate the dash number of the Old board that is to be replaced This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters The dash number brackets have purposely been left blank so as to eliminate errors confusion and updates LN9 AND LN9 GMA 10 04 2005 LINCOLN Q This part is obsolete and no longer available P 127 N P 127 N DOOR ASSEMBLY LN9F LN9FH amp LN9F GMA FRONT VIEW 21 22 20 REAR VIEW L7091 2 1 85B LELECTRIC P 127 N 1 P 127 N 1 Indicates a Change This Printing For Codes Below 8000 use parts marked X in Column 1 For Codes 8000 to 8700 use parts marked X in Column 2 For Codes Above 8700 use parts marked X in Column 3 For LN9F GMA use parts marked X in Column 4 ITEM DESCRIPTION PART NO 11213 4 5 6 7 89 Door Assembly Includes L6023 1
127. erate the gun trigger to open the flux valve start the travel and start the arc Guide the gun with two hands Place one hand on the gun to steady it Place the other hand on the cables just back of the gun handle When making the weld lean the gun slightly forward into the direction of travel Let the weight rest on the drive roll Let the travel unit do the work Figure 4 and Figure 5 Horizontal Fillet Weld Arrow shows direction of travel Position the gun so the electrode feeds directly into the corner of the seam Do this with the electrode sticking out and the flux valve closed This position is usually obtained when the gun handle is approximately perpendicular to the vertical plate Once the correct angle is established guiding is accomplished by keeping the flux cone lightly in contact with the vertical plate Be sure the travel guide wheel is parallel to the seam Operate the gun trigger to open the flux valve start the travel and start the arc Guide the gun with two hands Place one hand on the gun to steady it Press down lightly with this hand to increase the weight on the drive roll Place the other hand on the cables just back of the gun handle When making the weld lean the gun slightly forward into the direction of travel Let the weight rest on the drive roll Let the travel unit do the work Figure 6 Horizontal Lap Weld Arrow shows direction of travel The above horizontal fillet weld instructions a
128. es connected to power source output studs For DC 600 codes below 8200 only 1 When using two LN 9 wire feeders connect jumper on the power source terminal strip as shown between terminals amp P 2 When using two LN 8 wire feeders connect jumper to power source terminals N amp S 3 Wire feeder A amp B MUST BE OF SAME MODEL The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 3 3 V K318 DUAL PROCESS CONTACTOR KIT Assembly and Installation DC 400 CONNECTION TO TWO LN 8 s OR TWO LN 9 s FOR THE SAME POLARITY OPERATION Welding sad To negativa oput To potlivo ovtout Gwd on power source on power source NA work vera twadey 8 wire hedar Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Extend lead 21A and 21B using 14 or larger insulated wire physically suitable for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience these extended 21A and 21B leads shou
129. es risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER s TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gant
130. es v te ments mouill s entrer en contact avec des pi ces sous tension isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha d a lsole se da e terra 1 5 HTOSMELT FSU SUB RT ecu SHEE Ne SU WU ns e gt AXIS nA JU ui ol jad ye 24200 qe daa dau ule Y ic Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel intlammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e 35909 9 A5 os He AIX ole GA AQU al gl Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo o B EAUSGRCRENEREL CF CARR ER2ASTIBIBGNIBA AS 80 28378 SBsHA
131. ff the cable The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N6 2 6 DISASSEMBLY OF K116 SGUIRTGUN 1 Cable and Nozzle Disassembly is same as K115 or K126 2 Switch Housing Remove pistol grip assembly from the gun by removing the four screws which clamp the assembly to the handle and remove the one screw which holds the housing in the pistol grip handle Slip the aluminum housing out of the handle To remove the snap action switch from the housing look into the cavity with the threaded hole towards the floor The tight side of the two larger roll pins that hold the snap action switch is to the right Drive these pins to the left They can be easily removed when they clear the right side of the casting If trigger is to be replaced remove the two smaller roll pins in the same way Sec N6 2 7 GUN CABLES 1 Clean cables after using approximately 300 pounds of electrode Remove the cable from the wire feeder and lay it straight on the floor Remove the nozzle contact tip from the gun Using an air hose and only partial pressure gently blow out the cable from the gun end Too much pressure at the start will cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out Sec N6 2 8 GUN NOZZLES 1 Replace worn contact tips as reguired 2 Remove spatter from tip or extension guide after each ten minutes of arc time
132. flux flow when making relatively long welds or welding continuously The magnetic particles can also April 1987 cause porosity in the weld Sec N4 4 13 Fit the magnetic separator into the funnel or hopper FLUX TANK LOADING Pour the flux to be reclaimed into the top pan of the 1 Flux Tank Optional Either turn off the incoming air line or remove the guick 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 remove cap from the tank Using the funnel provided put 100 pounds of flux into the tank It is very important that only new or properly reclaimed flux be put in the tank Coarse particles and or magnetic particles will stop the flux feeding process New Lincoln flux is properly screened at the factory All reclaimed flux must be separately screened through a vibrated screen having 065 075 openings and be put through a magnetic separator The K310 vibrated screen and K58 Magnetic Separator are available for this purpose The screen in the funnel supplied with the tank has much larger openings and its only purpose is to keep paper and slag out of the tank Screw the tank cap back on and tighten hand tight Reconnect the incoming air line to the tank There will always be a small amount of air and possibly drops of water coming out of the end of the tube coiled under the tank This is an automatic disposal s
133. g tip to tip and can be used to measure the length cut off If the flux hose is taped on the extension cables or the gun cable it should be done in such a manner as not to deform or collapse the flux hose November 1979 Sec N2 2 7 FLUX TANK INSTALLATION Models LN 9S and LN 9SE See S14121 for installation of the K320 Flux Tank to wire feeder with K163 undercarriage The air reguired for the automatic flux feeding system can be obtained directly from the plant compressed air system as long as the air pressure is no greater than 120 psi 827kPa or less than 60 psi 414 kPa The flux tank is eguipped with a water separator and pressure regulator to reduce the air pressure As shipped the unit is set for 30 pounds per sguare inch 207 kPa which is the proper value for an 18 foot flux hose When an Extension Assembly is used and the flux hose is long set the air pressure at 45 psi 310 kPa when using 1 2 inch 12 7 mm I D hose and 55 psi 379 kPa when using 3 8 inch 9 5 mm I D hose The amount of air reguired for flux feeding will normally be less than 1 5 cubic feet per minute Connection of the incoming air hose is made at the street elbow which is made to receive 1 4 inch pipe thread A guick disconnect connector should be inserted between the elbow and the air hose proper Flux Hose Connection to Gun Using the hose clamp provided connect the flux hose to the flux tube at the rear of the gun If the flux hose i
134. ge position of the desired polarity for the process being used b Set the toggle switch to Constant Voltage c Set the Constant Voltage Control rheostat to Number 7 and the Current Control to 500 for CV sub arc processes For Innershield and other Open Arc Processes a Set Electrode Polarity switch to Constant Voltage position of the desired polarity for the process being used b Set the toggle switch to Constant Voltage c Set the Constant Voltage Control rheostat to Number 5 for Innershield and other open arc processes April 1987 910c Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 K161 POWER PACK WIRING DIAGRAM Connector that plugs into front of LN 6 LN 8 or LN 9 Output End gt 022 B 6 1 Amp fuse 32 Terminal strip FRE AU Ja af Tare lug on red lead for 60 Hz WA EE To power source or Power pack adapter box B H E kit terminal strip GND 12 4 For 50 hertz operation both the iN Control cable y red amp white No 54 leads must be connected to the No 54 on the terminal strip These numbers refer to circuit numbers 15803 1 amp fuse not used only and not to any number that may 10 15 82L on earlier units appear on the relay housing f the power source or contactor kit has terminals 31 32 and 4 but no terminal 1 connect leads 31 a
135. h K320 flux tank mounted on a K163 undercarriage A LN 7 LN 8 or LN 9 type wire feeder can be added April 1987 Shown with K357 and K319 attached Sec N3 3 21 K306 LN 9SE WIRE REEL AND FLUX TANK ASSEMBLY Includes the same frame as used in the K305 In addition there is a closed housing for the reel and hand crank for extension loading Also includes a handle for wire feeders and 64 of flux hose April 1987 Sec N3 3 22 K445 WIRE REEL ASSEMBLY An open mounting stand similar to the K376 but equipped with a K162 H 2 O D Spindle and K438 Readi Reel Adapter for 50 60 pound Readi Reel coils January 1989 The Lincoln Electric Company Cleveland Ohio 44117 1199 OPTIONAL FEATURES Sec N3 5 1 File as Sec K2 5 18 in IM 274 A K317 DUAL PROCESS KIT No Polarity Change The Dual Process Kit is a transfer device that connects two wire feeders to a single power source and enables each wire feeder to weld at a different procedure without changing any dials Simply actuating the circuit of the desired wire feeder turns the unit on and its controls set the complete procedure including the power source output level When used with a DC 600 the wire feeders can be set for different modes CV Innershield or CV Submerged Arc Both wire feeders will operate at the same polarity The unit is a small control box that mounts on the side of the power source and is connected to the welder terminal strip Eac
136. h wire feeder control cable is connected to the Kit The electrode of the wire feeder not being used will be hot although of course there will be no wire feed This usually is no problem since the unused gun or nozzle can be placed safely out of the way If however it is desired to have the unused electrode cold use a K318 Dual Process Contactor Kit connected for same polarity operation Maximum versatility is obtained when the Kit is used with a DC 600 power source The following chart shows the advantages that a DC 600 has over other welders The K317 should not be used with power sources other than those shown below Fang DC 400 DC 600 SAF 600 Obsolete or SA 800 Obsolete with K224 Solid State Remote Control R3S Obsolete Pulse Power 500 The output range is limited by the voltage change obtainable by the remote control The voltage range between the two procedures reguired may be outside the range covered by the remote control and it would be impossible to set the procedures without adjustment at the power source Although designed primarily for use with the LN 8 or LN 9 wire feeders the kit will also work with two LN 7 s when they are used with two remote control units or with two NA 3 s NA 4 s or NA 5 s 910c Assembly and Installation NODE SWITCHES CY SUBMERGED ARC x FOR CV INNERSHIELD POWER SOURCE MODE SWITCH MUST BE IN CY INNERSHI
137. hange obtainable by the remote control The voltage range between the two procedures reguired may be outside the range covered by the remote control and it would be impossible to set the procedure without adjustment at the power source Although designed primarily for use with the LN 8 or LN 9 wire feeders the kit will also work with two LN 7 s when they are used with two remote control units Installation If it is desired to mount the K318 on top of a DC 600 an 16552 mounting bracket is available Refer to the following connection diagrams to connect the dual process contactor kit to the power source and LN 8 or LN 9 wire feeders To connect the two wire feeder control cables remove the cover from the contactor kit for access to the terminal strips Run the cables through the two box connectors then under the L shaped brackets mounted on the bottom to keep the cables away from the contactors Connect the leads to the two terminal strips per the appropriate connection diagram If 50 hertz is used reconnect contactor coil leads per the wiring diagram 910c Assembly and Installation Opposite polarity operation DC 400 DC 600 M13720 R3S and SAM M13706 SAF 600 and SA 800 with solid state remote field control CV 400 Same polarity operation DC 400 DC 600 M13736 R3S and SAM M13705 SAF 600 and SA 800 with solid state remote field control M13703 PP500 CV 400 M14551 M13918 M13916
138. he LN 9 and also by cooling the motor with an air hose or fan When the protector is tripped the digital meter is lit but there will be zero reading The trigger circuit will not operate 3 Field Circuit Fuse The fuse on the P C board inside the control box protects the motor field circuit When the fuse is blown the digital meter is off and the trigger circuit will not operate The Lincoln Electric Company Cleveland Ohio 44117 1199 4 Grounding Lead Protector The frame of the LN 9 wire feed unit and the drive motor are grounded to the frame of the power source by a lead in the control cable An overload protector prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the gun trigger is pressed If such a grounding lead fault occurs the meter will still be on and will be reading However the trigger circuit will not operate To reset the circuit press the G L P Reset button 5 Voltage P C Board Fuse Not included on boards built prior to 1983 The 1 8 amp fast blow fuse protects the LN 9 circuitry from damage which may result from a ground or case faulted control lead If this fuse blows the LN 9 arc voltage sensing lead circuit will be opened see Section 6 e below and the LN 9 Troubleshooting Guide should be consulted to detect and clear the fault 6 Automatic Shutdown If the LN 9 voltage control is unable to supply the SET value of arc vol
139. henol end of the power input cable and the opposite end to the wire drive unit b Connect the Amphenol connector of the control cable on the extension assembly the one with threads on its O D to the connector on the input cable assembly c Remove the screws holding the cable clamp located near the rear of the wire reel base Put the control cable and the electrode cable under the clamp and install the screws On cables with more than one electrode cable leave the junction between the two or more cables and the single 4 0 stub behind the clamp so only the single electrode lead is under the clamp Connect the electrode cable of the input cable assembly to the brass block on the hand crank d Insert the connector on the conductor sheath of the extension assembly into the brass block of the hand crank assembly and tighten the locking screw with a 3 16 4 8 mm hex Allen wrench POLARIZED CONNECTOR INPUT CABLE ASSEMBLY WIRE DRIVE UNIT EXTENSION CABLE BRASS HAND BASE BLOCK CRANK e At the wire drive unit connect the Amphenol of the Extension control cable to the receptacle on the back of the LN 9 The Lincoln Electric Company Cleveland Ohio 44117 1199 f Remove the ingoing guide tube from the rear brass block and then plug the connector of the conductor sheath into the brass block Tighten the locking screw with a 3 16 4 8 mm hex Allen wrench The guide tube removed is not used when the extension assemb
140. hould slightly favor the horizontal plate The nozzle flux cone should miss the vertical plate by about 1 32 0 8 mm The gun handle must be 90 to the vertical plate when looking down from above Be certain the electrode has not been bent when making these adjustments c Hold the gun in proper position for welding Lower the rear wheel until it touches the horizontal plate Lock it into position The adjustment range of the rear wheel can be increased by moving the wheel from position A to B If using the nozzle extensions for long stickout procedures replace item 15 with the long guide roll arm item 16 d Slip the roller guide down until the two small rollers touch the vertical plate Lock it in position The nozzle flux cone should never drag on the vertical plate when welding The roller guides and rear wheel should be parallel to the travel unit drive wheel The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N4 4 15 continued Operating Instructions 165 K 110 Mechanized Hand Travel Unit FIGURE 1 600 A Gun Without Extended Stickout FIGURE 2 If the rear wheel must be clamped n the extreme forward position it s necessary to Insulate between the hose clamp amp the allen screw which 15 under the actuating lever duro paper or several thicknesses of friction tape will do 600 A Gun With Extended Stickout A plece of Position GON
141. iated When the switch is in the down position and the trigger is pressed the electrode will be electrically cold and no arc can be established The use of this switch permits the loading of the LN 9F with an electrically cold electrode February 1982 Sec N4 4 10 WIRE REEL LOADING 50 and 60 Pound Coils 1 To remove the wire reel from its shaft grasp the spring loaded knob and pull it out This straightens the knob so it seats into the shaft when released Remove the reel 2 Lay the reel flat on the floor loosen the spinner nut and remove the cover plate 3 Before cutting the tie wires place the coil of electrode on the reel so it unwinds as the reel rotates clockwise a Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires See photo Operating Instructions b When loading 030 035 045 and 052 solid wire or 1 16 5 64 3 32 1 8 045 052 Outershield wire be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil needed for trouble free wire feeding See photo c Put the cover plate on the reel so the four arms of the cover straddle and are in line with the spring loaded arms of the reel proper 4 Tighten the cover as much as possible by hand Do NOT hammer on the spinner nut arms 5 Cut and remove only the tie
142. in a 10 minute period expressed as a percentage Start Board Voltage Board Control Board Start Board with Pin connected Start Board with Pin A connected The Lincoln Electric Company Cleveland Ohio 44117 1199 NOTE Pins are Control behind Start Voltage Board plug Board Board Location of P C Boards on the LN 9F and 9FH Obsolete zy lal 3WM eon i ANA 301 F Control Board with Pin F connected This is recommended for most applications Pin S can be used when slower wire feed motor acceleration is needed normally long stickout applications LN 9 models above code 8991 do not use a start board Pins A amp B on these later models are located on the Voltage Board P N L6084 2 or higher The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 3 3 A Assembly and Installation CONNECTION OF LN 9 TO A SAF 600 OR SA 800 O OR OF USING A K224 SOLID STATE FIELD CONTROL Obsolete SAF 600 or SA 800 or control box 48 n Optional solid 1 4 state field control t Field control 0499 input cable E or73 69 4 24 4 2 31 32 75 76 77 70 74 C4 p r al li Auto LIEN 32 31 2 21GND4 A BC Tape up Lead 75 from Field Control Note Electrode polarity switches on power source LN 9 and field control must be set for same polarity Power
143. ing Bracket M13696 1 2 Toggle Switch T13381 2 X 3 Caution Decal T13470 1 X 4 Nameplate S16391 1 5 Number Plate T10726 125 1 X 6 Cover M13692 1 X 7 Case Welded Assembly S16191 1 X 8 Control Cable S16190 1 X 10 Box Connector T9639 1 2 X 12 Terminal Strip S8542 1 2 X 13 Number Plate T10726 126 1 X 14 Relay 1CR T13845 3 1 X 15 1 0 Sticker T12286 1 1 X 16 Relay 2CR S14293 7 1 X 17 1 0 Sticker T12286 2 1 X LN9 AND LN9 GMA 01 01 2007 LINCOLN P 127 R P 127 R K319 DUAL PROCEDURE KIT FEN So L6055 11 5 82M LN9 AND LN9 GMA LINCOLN P 1 96 P 127 R 1 P 127 R 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO GTY 1 2 67 89 1 Control Box L6054 1 X 2 Rheostat Knob T10491 4 3 Cover M13652 1 X 4 Insulation 516384 1 X 5 P C Board Assembly M13679 1 6 Nameplate S16382 1 X 7 Receptacle Assembly S13100 63 1 X 9 Insulating Tube T14767 4 X 10 Shaft Seal T14034 4 x Insulating Tube T7028 241 2 X Items Not Shown Gun Mounted Selector Switch amp Cable Assembly Includes S16383 1 3 pin Amphenol Connector 12020 16 1 X Cable Clamp 12024 4 1 Extension Cable Assembly Includes M13681 1 X 3 socket Amphenol Connector 12023 8 1 X 3 pin Amphenol Connector 12020 16 1 X Cable Clam
144. ing R3S or SAM welders De HER N F Refer to appropriate wire Due D feeder to power source pue i Gn connection diagram N G To make A feeder positive Wl polarity and S feeder negative U polarity reverse electrode y YN cables connected to power To A wire leader To wire feeder Source output studs electrode negative electrode positive N A A Connect the control cable ground lead to the frame terminai marked 777 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Extend lead 21A and 21B using 14 or larger insulated wire physically suitable for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience these extended M13916 21A and 21B leads should be taped to the welding work lead Each lead must 11 2 79 be connected directly to the work and leads must not be connected together For 50 Hz Operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B 910c Assembly and Installation Sec N2 3 3 T K318 DUAL PROCESS CONTACTOR KIT The Lincoln Electric Company Cleveland Ohio 44117 1199 DC 600 CONNECTIO
145. ins to the left They can be easily removed when they clear the right side of the casting Do not remove the smaller roll pins unless the trigger is being replaced The height of the Z spring controls the operating point of the switch with respect to the trigger movement Set the spring so the switch operates at about the midpoint of the trigger travel To remove the handle from the cable slip the spatter shield out of the front of the handle Remove the snap ring from the cable connector and the handle can then be slipped off the cable Sec N6 2 2 DISASSEMBLY OF SUBMERGED ARC SGUIRTGUN K114 Remove the cable from the wire feeder To disassemble the gun from the conductor cable proceed as follows refer to Sec N7 2 page E 1 Be sure the air is off and the pressure is released from the tank 2 If the gun still has filler wire in it clip end of wire and back the wire out of the gun 3 Loosen the screw holding the travel receptacle clamp item 8 Do not remove the nut from the screw This will allow the clamp and the travel plug to swing free 910c 4 Loosen the electrical connection clamping screw item 33 5 With the trigger bar item 10 in the off position grasp the gun tube item 5 in one hand and the cable handle item 28 in the other Pull the two units apart using a slight back and forth motion To disassemble the gun proceed as follows 1 Using a pair of needle nose pliers lift the end of the
146. ist Index aree tee meret RH E Pete YN re Appendix Waring Diagrams set eaw Te Na dT bete o YN Y ite TURIN At Back of Manual August 1996 The Lincoln Electric Company Cleveland Ohio 44117 1199 PRODUCT DESCRIPTION A new concept in semiautomatic welding a wire feeder which when used with an appropriate Lincoln power source takes the guesswork from procedure setting and procedure control This unit is designed to achieve higher Assembly and Installation guality control and weld guality levels more easily The arc voltage and wire feed speed can be set on a digital meter before the arc is struck and the procedure remains precisely set day in and day out on production jobs SEC N2 INSTALLATION Sec N2 2 MECHANICAL INSTALLATION LN 9N Wire Feed Mechanism set for 3 32 2 4 mm electrode diameter Sec N2 2 0 WIRE DRIVE The LN 9 semiautomatic wire feeder is available in either two or four roll wire drive models The two roll model utilizes two driven rolls to feed steel electrode and only a single driven roll for feeding aluminum electrode The four roll wire drive is similar to the two roll and uses some of the same components The most noticeable difference between the two is that four driven rolls are used instead of two for feeding all steel electrodes and two driven rolls with two undriven rolls are used for feeding aluminum electrodes instead of one Drive roll a
147. ld be taped to the welding work lead Each lead must be connected directly to the work and leads must not be connected together Sec N2 3 3 W K318 DUAL PROCESS CONTACTOR KIT N A Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N B Bolt and tape connections N C Tape up separately N D Put transfer switch in same polarity on feeders position N E Mode switches on contactor kit are not functional when used with the DC 400 N F Connection shown for negative polarity For positive polarity reverse electrode and work cables connected to power source output studs M14550 1 20 89B For 50 Hz Operation Disconnect both brown leads from terminal 31B and tape up each lead Untape both red leads and connect to 31B DC 400 CONNECTION TO TWO LN 8 s OR TWO LN 9 s FOR OPPOSITE POLARITY OPERATION a y zm _ v HIS We df T 1 YR EF Eis i al i times To A wwe tooder To ET wiro Hood alactrode posano Connect the control cable ground lead to the frame terminal marked 777 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded N B B Extend lead 21A and 21B using 14 or larger insulated wire physically suitable for the installation An S16586 remote
148. ll pressure if necessary can be tolerated However if the pressure reguired to properly feed the aluminum wire also permits bird nesting or excessive slippage results in aluminum pickup in the drive roll groove the loading on the wire by the gun cable or wire reel should be inspected and alleviated April 1987 The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation LN 9N Or 9HN Obsolete and Optional K163 Undercarriage Sec N2 2 3 WIRE FEED ROLLS AND GUIDE TUBES FOUR ROLL WIRE DRIVE SYSTEM 1 Release both guick release levers 2 Remove clamping collars from both drive shafts 3 Install one drive roll with the key and replace clamping collar Tighten screw 4 Slide the middle guide tube into place Do not tighten set screw 5 Install second drive roll with the key and replace clamping collar Tighten screw Note The middle guide tube may need to be pushed up tight against the first drive roll to allow room for installing the second roll 6 Center the middle guide tube and lock in place with its set screw 7 Remove idle roll guick release pins install idle rolls Replace pins 96Au LN 9SE LN 9S NOTE The Aluminum wire drive roll kits have one piece drive rolls and idle rolls with a larger chamfer on one side instead of gear teeth This larger chamfer side must face the gearbox when installed The side with the smaller chamfer and wire size stencil
149. lose the control box door and replace the door screws moon Mn LN 9F Control Box Electrical Connections Wire Feed Mechanism to Control Box a Making certain the cables are protected from any sharp corners which may damage their jackets mount the 16 foot control and electrode cable assembly along the boom so the end with the two right angle amphenol connectors terminating the control cables is at the wire feed mechanism b Connect the two right angle cable connectors to the receptacles on the wire feed mechanism c At the same end connect the electrode lead to the front brass block on the wire feed mechanism d At the control box end connect the two amphenol connectors of the cable assembly to the control box If more convenient for the installation the right angle connector housing can be rotated by removing the connector cable clamp and the two housing screws Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 2 8 continued repositioning the housing as desired and replacing the screws and clamp 4 Input Cable Connections to Control Box Connect the K196 input cable assembly to the LN 9F control box as follows a Connect the amphenol connector on the control cable to the receptacle on the bottom of the control box b Bolt the electrode lead from the power source to the electrode lead of the wire feed mechanism using the nut and bolt supplied Insulate
150. lso apply in making horizontal lap welds However since there is no vertical plate to lightly hold the cone against keeping the proper electrode angle must be done by eye The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N 4 4 15 continued Figure 7 Positioned Fillet Weld Attach the positioned fillet adapter Rotate the travel unit and adapter so the drive wheel rides in the seam ahead of the weld Position the gun with the gun nozzle perpendicular to the seam Guide the gun with two hands Tilt it slightly forward in the direction of travel when making the weld November 1990 Operating Instructions Figure 6 Operating Instructions The Lincoln Electric Company Cleveland Ohio 44117 1199 File as Sec K3 2 4 in IM 274 If the fillet angle varies from one weld to another readjustment of the roller guide may be necessary For FILLET GUIDE OPTIONAL K70 example assume the Fillet Guide was adjusted for an The Fillet Guide is designed to help guide Sguirtgun K114 angle of 90 If the fillet angle of the next weld is 95 so the operator can make more uniform horizontal fillet the cone may drag on the vertical plate Readjust the welds with less effort It consists of a vertical plate roller roller guide guide and a rear wheel assembly Once the roller guide and e Recheck the electrode alignment after tightening the rear wheel are adjusted the weld is easily made by gently guides and before making the wel
151. ly SET voltage See Out of Range Shutdown Sec N6 6 2 See How To Make Submerged Arc Welds S604 or Innershield Production Welding Guide N675 See Starting Characteristics Sec N4 4 17 for proper acceleration setting See Voltage Control Response Sec N4 4 18 and the appropriate power source connection diagram The LN 9 Comprehensive Troubleshooting Guide IM 294 TS is distributed to Lincoln Service Stations Voltage P C boards built prior to 1983 do not have fuse protection The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N6 6 2 OUT OF RANGE SHUTDOWN Although out of range shutdown can occur with all power sources when working with very low or very high arc voltages it is most likely to occur when using the R3S models with the somewhat limited voltage range of the various taps For instance if the R3S 400 triangle tap setting is for 31 volts the range of control from the remote circuit is approximately 7 volts i e 27 1 2 to 34 1 2 volts at nominal input voltage If the LN 9 controls are set for 29 volts and the input voltage to the R3S goes up it may not be possible for the LN 9 control circuit to hold the 29 volts so the welding will shut down By changing to the 27 volt triangle setting the range will be approximately 23 1 2 to 30 1 2 volts and at a high input voltage there will be sufficient control to hold the SET arc voltage On these machines if the L
152. ly is installed g If using welding currents over 450 amperes connect a length of 1 0 cable between the brass block on the hand crank and the input strap located in the wire drive unit Tape this cable to the extension assembly Proper cable lengths are as follows 22 1 2 ft extension 26 7 8 m M5906 106 45 ft extension 46 13 8 m M5906 104 h A handle for the wire feeder is provided with wire reel mounts eguipped with the hand crank and is mounted to the wire drive unit in the following manner Remove the two self tapping screws that hold the hinge pin in captivity push the hinge pin out leaving the covers intact Place the handle into the slots provided push the hinge pin back into the assembly making sure that the pin goes through the holes in the handle Put the two self tapping screws back into their respective positions and tighten securely K306 Wire Reel and Flux Tank Assembly The Lincoln Electric Company Cleveland Ohio 44117 1199 i If the extension is being used with a K306 Wire Reel Flux Tank assembly the hose attached to the bottom of the flux tank may have to be shortened This hose is 64 19 5 mm feet long and is the correct length for use with the 45 13 7 mm foot extension If a 22 1 2 6 9 mm foot extension is to be used cut off 22 1 2 6 9 mm feet of the flux hose to give the correct length of 41 1 2 feet 12 6 mm The conductor cable of the extension assembly is 22 1 2 6 9 mm feet lon
153. moved Turn off power source before installing or servicing Do not touch electrically hot parts ELECTRIC SHOCK 3 Turn the input power to the can kill welding power source off at the fuse box before working in the terminal strip Keep away from moving parts AS MOVING PARTS can injure Only qualified personnel should install use or service this equipment Sec N2 3 1 INPUT CABLE CONNECTIONS TO THE POWER SOURCE Input Power 115VAC 4 5A is supplied by the power souce Connect to appropriate Lincoln power source as follows 1 If using a multiprocess power source SAM SA 800 SAF 600 DC 400 DC 600 be sure it is properly set for the welding process being used per Sections N2 3 3 C and D 2 Connect the LN 9 input cable to the power source exactly as specified on the appropriate connection diagram See Sec N2 3 3 Include all jumpers on the terminal strips as shown on the diagrams Do not add any additional jumpers 3 Depending on the power source and process to be used the jumpers on the LN 9 Voltage Board and Start Board on models where used may have to be changed As shipped the LN 9 is connected for use with Lincoln DC type power sources For other power sources refer to the appropriate connection diagram 4 Connect a work lead of sufficient size and length per the table between the Work stud on the power source and the work Be sure the c
154. must be installed facing out 8 Loosen the ingoing guide tube clamping screw Install the guide tube which is stenciled in The guide tube should be slid in until it almost touches the drive rolls Tighten the locking screw 9 Install the outgoing guide tube with its plastic insert through the front brass block Tighten the locking screw so its dog point goes into the groove in the O D of the guide tube August 1996 Assembly and Installation Sec N2 2 3 continued ADJUSTMENT SCREW Sec N2 2 4 SETTING THE DRIVE ROLL SPRING PRESSURE FOUR ROLL WIRE DRIVE SYSTEM NOTE The drive rolls are stenciled with the wire size for which they are designed If a wire size other than that stamped on the drive rolls is to be used the drive roll and guide tubes will have to be changed Drive rolls stamped with a C suffix to the wire size range are recommended specifically for use with cored wires Because every feeding situation is different the four roll wire drive does not have graduated markings with wire sizes indicated on it A recommended starting pressure is indicated below for each applicable wire size and type Depending on the particular application these starting pressures may need to be adjusted up or down Some of the variables that affect tension settings are type and brand of electrode surface condition lubrication hardness type and length of cables and conduits routings of cables and conduits and drive
155. n Refer to LN 9 Operating Manual for required polarity connections S17185 8 2 90F 910c N A N B N C N D N E N F N A N B N C N D N E N F N G N H Assembly and Installation A WARNING Do not operate with covers removed Disconnect welding power source before servicing Do not touch electrically live parts ELECTRIC SHOCK Only qualified persons should can kill install use or service this machine Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications See LN 8 or LN 9 Operating Manual for proper sizes Extend lead 21 using 14 AWG or larger insulated wire physically suitable for the installation An S16586 LENGTH remote voltage sensing work lead is available for this purpose Connect 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 Tape up bolted connection Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip The power source grounding terminal marked 7 and located near the power source input power connections must be properly connected to electrical ground per the power source operating manual Connect control leads to terminal strip as follows LN 8 75 LN 9 075 76 Bto 77 Cto 7
156. nd 32 from the power pack to their respective terminals on the terminal strip Connect lead 8 from the power pack to terminal 4 on the terminal strip Tape separately the lugs on leads 1 and 4 Connect the green lead from the power pack to the frame of the power source or contactor kit by means of the frame stud near the terminal strip or other secure electrical connection If the power source or contactor kit has terminals 31 32 4 and 1 connect leads 31 32 4 and 1 from the power pack to their respective terminals on the terminal strip Tape up the lug on lead 8 Connect the green lead from the power pack to the power source or contactor kit by means of the frame stud near the terminal strip or other secure electrical connection K114 gun control cable Power pack a Start stop switch adapter receptacle 8 D N i These leads used de ji 54 only for guns eguipped for travel unit 12 Brown or Blue K110 Hand travel 750Q K6L Squirtmobile 510Q Resistor Travel motor field Travel speed Travel motor armature NOTE Limitof 1 2 on all angles unless otherwise specified T12309 AU 6 4 e 10 15 82L Limit of 1 64 on all fractional dimensions unless otherwise specified Limit of 002 on all decimal dimensions unless otherwise specified The Lincoln Electric Company Cleveland Ohio 44117 1199 Assembly and Installation Sec N2 3 3 D INTRODUCTION TO DC 600 COMPONENTS NOT
157. nd guide tube kits for both wire drives are available as follows 91Oc NOE GE e A 2 Roli Wire Drive 4 Roll Wire Drive 7 64 120 Cored 28 30 mm KP502 120 KP545 120 1068 3732 3 32 3 32 1 7 2 4 mm 1 6 mm 1 16 Solid 1 16 1 16 1 6 mm 045 052 Cored 10 14 mm 052C 052C 1 0 1 4 mm 030 035 Solid 1 16 KP503 1 16A KP546 1 16A 1 6 mm 1 2 mm 035 5 Aluminum Electrodes Assembly and Installation Sec N2 2 0 continued The drive rolls for 045 062 1 0 1 6 mm cored wire sizes and all wire sizes of 068 1 8 mm and above use knurled V groove rolls The smaller solid wire sizes are driven with smooth V groove rolls The amount of driving force on the electrode should be just under the buckling point of the electrode The spring loaded drive roll assembly of the two roll wire drive has a nameplate with graduations on it so that the spring can be properly set for the wire size being used The spring loaded guick release drive roll mechanisms for the four roll wire drive do not have graduations because of the wide variety of dereeler and cable configurations that are possible See following Sections on setting the drive roll spring pressure for two or four drive roll systems Sec N2 2 1 WIRE FEED ROLLS AND GUIDE TUBES TWO ROLL WIRE DRIVE SYSTEM The drive rolls and guide tubes for the wire size specified on the machine order are shipped loos
158. njure Only qualified personnel should install use or service this equipment Sec N5 5 1 DRIVE ROLLS AND GUIDE TUBES After every coil of wire inspect the drive rolls and guide tubes and clean as necessary The drive rolls can be brushed with a wire brush Do not use a solvent on the outside drive roll as it may wash the lubricant out of the drive roll bearing The drive rolls and guide tubes are stamped with the wire size range for which they are designed If a wire size other than that stamped on the drive roll is to be used the drive rolls and guide tubes have to be changed The inner drive rolls using the knurled V Groove design wire have a double set of teeth so they can be reversed for additional life Between the two knurled rolls for 068 thru 120 is a shim washer which limits the damage to the wire to a minimum should wire feeding problems occur When drive rolls are interchanged leave the three socket head screws of the roll assembly loose until it is re assembled on the drive shaft Then tighten all three Be sure the roll faces and spacer faces are thoroughly cleaned before re assembly Drive rolls for 1 16 and smaller solid wire using the smooth V Groove design have no teeth They are not reversible October 1991 Sec N5 5 2 WIRE DRIVE MOTOR AND GEAR BOX Every year examine the gear box Paint the gear teeth with moly disulfide filled grease Lincoln Spec E2322 such as Non Fluid Oil
159. non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which reguire special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be reguired Additional precautions are also reguired when welding on galvanized steel The operation of welding fume control eguipment is affected by various factors including proper use and positioning of the eguipment maintenance of the eguipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat an
160. ntrol cable connect lead 76 to 76 field control lead 75 and 77 to 77 field control lead POWER SOURCE SETTINGS Turn Power Source OFF SAF 600 or SA 800 Type O or OF with K224 Obsolete Set power source Electrode Polarity switch to desired position Set Voltage control to maximum for higher voltage applications above 25 volts and mid range for low voltage applications For Submerged Arc Applications Set Voltage Range switch to High Connect lead from contactor box to the appropriate Submerged Arc tap for the current being used For Open Arc Processes Set Voltage Range switch to Low Connect lead from contactor box to the Innershield tap 910 516284 6 28 85N K224 Solid State Remote Field Control Set the toggle switch on the K224 to the same polarity as the power source April 1987 NOTE Refer to Sec N2 3 2 for Control Board pin placement Assembly and Installation Sec N2 3 3 B CONNECTION OF LN 9 TO AN IDEALARC R3S 400 600 OR 800 WITHOUT LINE VOLTAGE COMPENSATOR Obsolete The Lincoln Electric Company Cleveland Ohio 44117 1199 NOTE In the event the R3S is equipped with a line voltage compensator it should be disconnected before connecting the LN 9 N E Add jumper from 75 to 76 using nsulated copper wire N A To LN 9 input cable plug Dos 1 EN N F ND 7LN 9 Control cable Negative Positive Electrode cable
161. o wire feeder frame N P S Terminal Strip Codes Below 8200 only This is used for proper starting N and P Jumpered Provides proper DC 600 starting when connected to LN 9 N and S Jumpered Provides proper DC 600 starting when connected to other type wire feeders Not Preset Not recommended for short circuiting transfer January 1989 Assembly and Installation The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 3 3 D continued coe ARC WELDER output DEALARC DC T 600 WAM CLASS gas DC ARC WELDER n nn T1 Ub a DC 600 Control Board for Codes Between 8045 and 8200 NOTE Only 2 pins on P C Board NOTE This photo is for all processes except NR 203 elec trodes Pin I is used for NR 203 electrodes CONTRO A1 BC 606 OUTPUT j November 1979 AU INHERSHIELD STICK CDNTROL SUBMERGED ARC REMOTE ARC WELDER Mode and Circuit Polarity Switch on DC 600 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 3 3 E CONNECTION OF LN 8 OR LN 9 TO DC 600 Assembly and Installation NOTE Pay particular attention to note N E A jumper must be placed between N and P on the DC 600 N P S terminal strip Codes below 8200 only To LN 8 or LN 9 input cable plug Power source N G Control cable Negative Electrode cable to wire feed unit 1 work Above diagram shows electrode c
162. o not allow the electrode to contact the case of the wire feeder or uninsulated part of its wire reel stand when the gun trigger is activated 2 Be sure that all work lead connections to the work make tight metal to metal electrical contact 3 Do not allow excess electrode cable or work cable that is coiled up to be placed closer than three feet to the wire feeder The magnetic field that is generated by welding current going through the coiled cable can falsely activate the G L P April 1987 The Lincoln Electric Company Cleveland Ohio 44117 1199 Maintenance SEC N6 MAINTENANCE OF GUN AND CABLE ASSEMBLIES SARWARNING Have an electrician install and service th s eguipment Turn the input power off at the fuse box before working on eguipment Do not touch electrically hot parts ELECTRIC SHOCK can kill A SUBMERGED ARC GUNS Sec N6 2 1 DISASSEMBLY OF SUBMERGED ARC SGUIRTGUNS K113 AND K112 To remove the nozzle from the gun loosen the socket head screw in the gun handle and pull the nozzle straight out To reinstall insert the nozzle into the gun handle Push it in as far as possible and tighten the socket head screw To disassemble the switch housing from these guns remove the four screws holding the saddle around the gun handle Then hold the switch housing with the cable toward the floor and look into the switch cavity The tight side of the larger roll pins is to the right Drive these p
163. oll Spring Pressure for the correct procedure to set the idle roll spring pressure screw October 1991 Sec N4 4 3 CIRCUIT POLARITY SWITCH Set the switch to the same polarity as the electrode lead connection to the power source If the switch is not set for the correct polarity the wire feeder will stop welding shortly after the arc is struck See Item F in Troubleshooting Section N6 February 1980 Sec N4 4 4 READING ARC VOLTAGE Lincoln specified procedures give voltage readings taken between the work and the gun cable brass connection block of the LN 9 To match these voltage readings the latest connection diagrams show the 21 lead of the LN 9 control cable being extended and connected directly to the work instead of 421 on the power source terminal strip or Dual Process Kit terminal strip This extended lead must be connected directly to the work and when using a Dual Process Kit extended individually for each LN 9 This extended 21 lead connection replaces the need for the Direct Work Lead Jack and the 15 foot direct work lead both supplied with LN 9 models with Codes under 8200 Older unit installations which are not connected per the latest connection diagrams can be either reconnected or the 15 foot direct work lead plug can be inserted into the jack and its alligator clip connected directly to the work In early 1983 LN 9 models were provided with a guick connect terminal splice connection in the
164. onnected positive To change polarity turn power off reverse the electrode and work leads at the power source and position the switch on power source to proper polarity For optimum performance with the LN 9 DC 600 s with codes 8202 and above are preferred S16367 6 28 85N POWER SOURCE SETTINGS DC 600 All Codes Turn Power Source OFF Adjust the Power Source DC 600 a Connect electrode lead to terminal of desired polarity b Set toggle switch to same polarity as the electrode cable connection c Set toggle switch to Remote d Set mode switch to the desired position for the process to be used Codes 8000 8045 For Sub Arc 1 Set mode switch to CV sub arc 2 White lead on Control P C Board is connected to Pin M and blue lead is connected to W For all Open Arc Processes Except NR 302 and NR 203 Electrodes 1 Set mode switch to CV Innershield 2 White lead on Control P C Board is connected to Pin M and blue lead is connected to W 910c N B Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N C Extend lead 21 using 14 or larger insulated wire physically suitable for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For convenience thi
165. onnection to the work makes tight metal to metal contact Current Amps 60 Duty Cycle Two 3 0 August 1996 96Au Sec N2 3 2 EQUIPMENT COMPONENTS NOTE There are references in this manual in the text and the connection diagrams to P C boards and their jumpers and other equipment components The following descriptions and photographs should assist in locating them in order to make the proper connections or settings 1 Control Board Pin F Fast Acceleration Pin S Slow Acceleration Time required for wire feed speed to go from 0 to preset wire feed speed 2 Voltage Board Pin F Fast dynamic response at the arc Pin S Slow dynamic response at the arc 3 Start Board below Code 9087 Pin A Permits voltage control to start and weld with the response selected on the voltage board Pin B Permits voltage control to start with the response selected on the voltage board then shortly after establishing the arc an additional slow dynamic response is added NOTE For LN 9 Codes 9088 and higher the voltage board and start board are combined into one 4a Trigger Interlock below Code 7981 On position keeps the trigger circuit energized once the arc is established without holding the trigger until the arc is broken 4b Trigger Interlock and Hot Cold Wire Feed Switch above Code 7980 This three position switch perform
166. or as reguired 3 Replace worn spring liners in nozzles The life of the liner can be doubled by rotating liner 180 The liner can be pulled out the back end of the nozzle by wedging the blade of a small screwdriver in the I D and pulling 4 Internal parts of nozzles can be removed and replaced by removing the internal hollow lock set screw from the contact tip end of the nozzle with a 5 32 or 3 16 Allen wrench The ceramic insert and retainer will normally fall out the end of the nozzle but if they do not gently drive the spring liner towards the outgoing end of the nozzle See appropriate parts list page for construction details and replaceable parts For those guns where similar nozzles are used for different wire sizes note the identifying wire size that is stenciled or modeled in an area Close to the incoming end When reassembling nozzle make certain the ceramic nozzle insert if used is placed next to the spring liner The hollow lock set screw is to be tightened to give the dimension specified 96Au Maintenance below as measured from the end of the nozzle to the hollow lock set screw Gun K115 K116 K126 K206 K289 5 64 K289 3 32 and 120 K309 Nozzle Spring Liner Ceramic Insert Insert Retainer Hollow lock Set Screw C LINCONDITIONER GUNS Sec N6 2 9 1 For K206 request IM 548 2 For K289 request IM 549 3 For K309 request IM 550 August 1996 D GMAW FCAW GUN AND CAB
167. or molded in an area close to the incoming end When reassembling nozzle make certain the ceramic nozzle insert if used is placed next to the spring liner The hollow lock set screw is to be tightened to give the dimension specified below as measured from the end of the nozzle to the hollow lock set screw K 112 500 K 113 38 114 38 Nozzle Spring Liner Ceramic Insert Insert Retainer Hollow lock Set Screw Not used on K112 and K114 B INNERSHIELD GUNS Sec N6 2 5 DISASSEMBLY OF K126 K115 SQUIRTGUNS 1 Nozzle To remove nozzle from gun loosen socket head screw in gun handle with 3 16 hex key and pull nozzle straight out To reinstall insert the nozzle push in as far as possible and tighten screw 2 Switch Housing Remove the four screws that hold the switch housing to the saddle around the gun handle To remove the snap action switch from the housing hold the switch housing with the cable towards the floor and look into the switch cavity The tight side of the two larger roll pins that hold the snap action switch is to the right Drive these pins to the left They can be easily removed when they clear the right side of the casting If trigger is to be replaced remove the two smaller roll pins in the same way 3 Cable To remove cable from handle remove nozzle and slip the spatter shield out of the front of the handle Remove the snap ring from the cable connector and slip handle o
168. orking on the eguipment Install eguipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the eguipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information LINCOLN 8 E SAFETY PRECAUTIONS DE SURETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes Sdret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le cable de soudage et la machine a souder en bon et s r tat defonctionnement
169. osition 2 The Lincoln Electric Company Cleveland Ohio 44117 1199 TROUBLESHOOTING 1 Unit welds at one pro 1 Defective selector switch or cedure only relay Replace defective parts October 1991 Sec N3 5 4 K422 1 PULSE POWER FEEDER CONVERSION KIT K422 2 for LN 9 model codes below 9100 Required for proper pulse welding operation with the Pulse Power 500 power source January 1989 Sec N3 5 5 K392 POWER EXTENDED WIRE DRIVE For LN 9 model codes 8180 and higher Permits extending gun and cable up to 80 feet from wire feeder January 1989 Sec N3 5 6 K425 GAS SOLENOID KIT For LN 9 models above code 9131 except for LN 9F models Mounts outside the wire drive section and connects to the 115V AC auxiliary power connections per the instructions M15199 included with the kit K437 GAS SOLENOID KIT For all LN 9F models and LN 9 model codes below 9132 Mounts to the outside front of the feeder case and connects to 115V AC auxiliary power connections inside the feeder per the instructions M15253 included in the kit January 1989 The Lincoln Electric Company Cleveland Ohio 44117 1199 Operating Instructions SEC N4 OPERATING INSTRUCTIONS Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground AR di Always wear dry insulating gloves can kill Keep your head out of fumes Us
170. ote voltage o o sensing work lead is available for this purpose Connect it o l o i 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 This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 9 s which have a direct work lead jack If using an older LN 8 control cable connect lead 76 to 75 on terminal strip connect leads 75 and 77 to 76 on terminal strip N D The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual Tape up bolted connection White jumper on voltage board To Pin F for open arc processes or to Pin S for sub merged arc process Eletrodo cable Blue jumper on voltage board later units only or on start to wire feed unit board earlier units to Pin A N E Remove SAM portable field control and connect LN 9 control Fe work cable Connect the control cable ground lead to the frame terminal marked S16286 77 near the power source terminal strip or to an unpainted frame 6 28 85N screw The power source must be grounded properly POWER SOURCE SETTINGS Turn Power Source OFF NOTE Refer to Sec N2 3 2 for Control Board pin SAM Motor Generator or Engine Welder for Sub placement merged Arc Applications a Set Electrode Polarity switch to Variable Volta
171. p 12024 4 2 X LN9 AND LN9 GMA LINCOLN E 10 04 2005 P 127 S P 127 S INSTRUMENT PANEL LN9F LN9FH amp LN9F GMA 55 VAV wv M M13647 2 10 95D LN9 AND LN9 GMA LINCOLN P 1 96 P 127 S 1 P 127 S 1 Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 1 2 67 89 Sub Panel Assembly Includes Below Code 8000 13647 1 Sub Panel Assembly Includes Above Code 8000 LNOF amp FH M13647 1 1 Sub Panel Assembly Includes LN9F GMA M13647 1 1 X 1 Sub Panel Below Code 8000 M13626 1 Sub Panel Above Code 8000 M13872 1 1 X 2 Control Printed Circuit Board LN9F 4 FH L6019 1 X 2 Control Printed Circuit Board LN9F GMA L7253 1 X Below Code 10352 2 Control Printed Circuit Board LN9F GMA Above Code 10352 L10068 1 Plastic Expansion Nut S14020 3 4 X Self Tapping Screw S8025 71 4 X 3 Power Printed Circuit Board LN9F amp FH L6043 1 X 3 Control Printed Circuit Board LN9F GMA L7265 2 1 X Plastic Expansion Nut 14020 3 5 x Self Tapping Screw 8025 71 5 X 4 Trigger Printed Circuit Board Below Code 8000 M13630 1 X 4 Trigger Printed Circuit Board Above Code 8000 M13861 1 X Plastic Expansion Nut S1402
172. p 4 Roll LN9 AND LN9 GMA LINCOLN P P 127 D 1 P 127 D 1 Use Column 1 for LN9 LN9H LN9 GMA 2 Roll Drive Use Column 2 for LN9 and LN9 GMA 4 Roll Drive Indicates a Change This Printing ITEM DESCRIPTION PART NO QTY 12 617 89 1 Warning Decal M16196 1 2 Door Assembly Below Code 9000 M11490 1 1 2 Door Assembly Above Code 9000 M14850 2 0 1 IX 2 Door Assembly Red M16806 1 1X 3 Meter Panel Assembly See P127 G 1 4A Nameplate LN9 Only S16279 1 4A Nameplate LN9H Only S16623 1 X 4A Nameplate LN9 GMA S18003 1 4A Nameplate LN9 4 Roll Drive S20424 1 1 4A Nameplate LN9 GMA 4 Roll Drive S20424 2 1 4B Self Tapping Screw S8025 70 4 5 Hinge Pin M8809 53 1 6 Meter Panel Enclosure Except LN9 GMA 2 amp 4 Roll S16502 1 Drive amp LN9 4 Roll Drive 6 Meter Panel Enclosure LN9 GMA 2 amp 4 Roll Drive S18005 1 6 Meter Panel Enclosure LN9 4 Roll Drive S16502 1 1 IX 6 Meter Panel Enclosure LN9 GMA 4 Roll Drive S18005 1 1 7 Grommet Strip T12823 14 1 8A Thread Cutting Screw S9225 36 1 8B Lock Washer T9695 1 1 8C Hex Nut 10 24 2 9 Drive Roll Decal S17973 1 9 Drive Roll Decal Below Code 10351 S20101 1 9 Drive Roll Above Code 10351 S22739 2 1 10
173. power source and process The Lincoln Electric Company Cleveland Ohio 44117 1199 Replace contacttip Inspect repair or replace as necessary Be sure the following connections are tight electrode cable to wire feeder and power source work cable to power source and work gun cable to wire feeder contact block gun nozzle to body and contact tip to nozzle See appropriate power source connection diagram Reset circuit breaker See Circuit Breaker in Sec 5 5 7 Replace fuse See Field Circuit Fuse in Sec N5 5 7 Check that power source is on If so check power source AC fuse Let unit cool until protector resets See Motor Thermal Protection in Sec N5 5 7 Clear fault between electrode circuit and wire feeder frame and then press GLP Reset button See Grounding Lead Protector in Sec N5 5 7 Set Polarity Switches in proper position See Electrode Polarity Switch Sec N4 4 3 Fully engage Work Lead Plug into jack Connect Direct Work Lead Clip to work See Reading Arc Voltage Sec N4 4 4 R3S or DC power source voltage control switch must be set to REMOTE See Sec N2 3 3 B Refer to connection diagram for Lincoln power source being used Refer to Section 4 of the Comprehensive Troubleshooting Guide to determine cause of fuse blowing Reset output range controls of power source so it can supp
174. r Assembly Below Code 9100 14623 2 1 14A Reed Switch amp Energizer Assembly Below Code 9100 S14623 3 14B Energizer Above Code 9100 L7392 1 XX 14C Self Screw Not Shown S8025 13 1 15A Hex Head Cap Screw Above Code 9100 1 2 13x1 000 1 15A Hex Head Screw Below Code 9100 1 4 20x2 00 4 15B Lock Washer Above Code 9100 T9860 2 1 15C Hex Jam Nut Above Code 9100 1 2 13 1 16 Hex Head Cap Screw 1 2 13x 750 2 18 Outgoing Conductor Block L6872 2 1 19 Plain Washer Above Code 9100 S9262 120 2 dE 20 Plain Washer S9262 23 4 X X 21 Lock Washer E106A 2 4 X X 22 Hex Head Cap Screw 1 4 20x2 00 4 23 Hollow Set Screw S11604 28 4 24 Incoming Conductor Block L6872 1 1 25 Locator Bushing 112189 2 26 Incoming Wire Guide T12272 1 27 Insulation M12137 1 X X 28 Gear Box Mounting Plate M11460 1 29A Hex Head Screw 5 16 18x 75 4 29B Plain Washer S9262 121 4 IXIX XIX 29C Lock Washer E106A 14 4 30 Yoke Assembly S13454 1 am 30 Yoke Assembl 16731 1 31 Pin T12206 3 1 32 Hollow Set Screw S11604 8 1 33 Button Head Set Screw T11551 5 1 34 Compression Spring T10247 10 1 35 Yoke Setting Indicator T12689 1 36 Button Head Screw T11551 1 1 37 Key Below Code 10300 M8776 31 1 38 Collar Assembly Below Code 1030
175. r E106A 13 2 2 Cover Assembly T14326 1 3A 6 32 375 Phillips Round Head Screw CF000108 1 TXIXTXIX 3B Lock Washer E106A 13 1 114246 1 4A 8 32 375 Round Head Screw CF000006 2 4B Lock Washer T4291 A 2 4C Plain Washer Not Shown S9262 3 2 5 Plain Washer Shim S16268 1 4 6 Slotted Disc S16180 1 IXIXIXIX 7 Tachometer Pick UP P C Board M14700 1 IXIXIXIX 8 Pick Up Housing Assembly M13578 1 1 9 Insulator S16267 1 10 Heat Sink 13579 1 11A 8 32 375 Round Head Screw CF000006 2 11B Lock Washer T4291 A 2 XIXTXIX 12 Drive Motor Assembly LN9 includes 12A amp 128 L5974 1 1 12 Drive Motor Pinion amp Shaft includes S16470 1 1 X Codes 8420 8180 9087 9134 9958 12 Drive Motor Assembly includes 12A amp 128 L5974 2 1 12A Drive Motor Pinion amp Shaft includes S16470 2 1 Codes 8921 8670 9089 8421 8670 12 Drive Motor Assembly includes 12A 8 12B L5974 3 1 12A Drive Motor Pinion amp Shaft includes M13862 1 0 1 Codes 8178 8422 8669 9088 12 Drive Motor Assembly includes 12A amp 128 L5974 4 1 X 12A Drive Motor Pinon amp Shaft includes M13862 2 1 eX Codes 8423 8671 9090 12B Pinon Gear S15013 4 1 12B Pinon Gear S16612 1 X 12C Roll Pin Gear to Shaft T9967 33 1 X 12D Brush Cap Stature M13312
176. r convenience this extended 21 lead should be taped to the welding work lead If the 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 terminal strip Note that this is not the preferred connection because it adds error to the wire feeder voltmeter reading Tape up bolted connection Connect the control cable ground lead to the frame terminal marked 77 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 electrical ground per the power source operating manual f using an older LN 8 control cable Connect lead 75 to 75 on terminal strip connect lead 76 to 76 on terminal strip connect lead 77 to 77 on the terminal strip The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual White jumper on voltage board to pin S Blue jumper on voltage board later units only or on start board earlier units to pin B N G If lead 21 is to be connected to the terminal strip connect to the 21 terminal that matches work polarity This connection must be changed whenever the electrode polarity is changed The Lincoln Electric Company Cleveland Ohio 44117 1199 CONNECTION OF LN 8 OR LN 9 TO PULSE POWER 500 To LN 8 or LN 9 inpu
177. r the appropriate connection diagram Replace cover on Kit and unit is ready to operate Assembly and Installation Sec N3 5 1 continued OPERATION For DC 600 set the mode switch on the front of the power source to CV Innershield Set the mode switches on the kit to the position reguired by the process used on the wire feeder On all other power sources the mode switches have no effect To set procedures weld with A wire feeder and set procedure with its control dials Then weld with B wire feeder and set the procedure with its control dials With the LN 9 it is not necessary to weld Each unit will now weld at its reguired procedure when its gun trigger is actuated Do not try to weld with both units simultaneously because the procedures will not be correct and the power source may be overloaded WARNING Place unused gun so electrode does not touch work wire feeder case or other metal because both electrodes become electrically hot when either gun trigger is pulled The Lincoln Electric Company Cleveland Ohio 44117 1199 TROUBLESHOOTING 1 No control of power source output 2 Poor bead shape or arc response when using DC 600 power source 3 Poor starting when using DC 600 below Code 8200 a DC 600 or R3S power source toggle switch not set to remote Set power source per its instruction manual b Defective K317 relay replace relay c Defective wire feeder control rheostat R
178. re and gas and either NR 203 or NR 302 Innershield electrodes Codes Between 8045 and 8200 As shipped these codes had the control P C board jumper connected for optimum welding on all processes except NR 203 When using NR 203 it is necessary to change the jumper on the control board for optimum arc stability per the following instructions All Processes Except NR 203 White jumper on NR 203 White jumper on I Codes Above 8200 No control P C board jumper lead connections are necessary a B lt CV SUB ARC lt CV INNERS TIME TIME 91Oc CV Innershield Fast current response to a change in voltage CV Submerged Arc Very slow current response to a change in voltage CC Stick Option Sub Arc Constant Current characte ristics For stick and for some sub arc applications when using wire feeders other than the LN 9 Machine Remote Switch This switch is set in remote position for voltage control at wire feeder Circuit Polarity Switch This switch must be set to the same polarity as the elec trode cable connection Terminal Strip Connections 2 and 4 Output circuit 31 and 32 115 AC power 75 76 77 Control lead connections for remote control of power source output 80 and 81 Leads used to allow the selection of CV Innershield or CV submerged arc at a remote position K317 or K318 Grounding Terminal Connects power source frame t
179. rk or set to the cored 3 32 mark if 062 is not labeled These settings should be accurate enough so that there is no need to re adjust unless the electrode is unusually soft c For wire sizes from 068 thru 120 1 7 3 0 mm idle roll pressure should be set with wire in the system For solid wire the indicator should be lined up with the solid wire settings For cored wire the indicator should be lined up with the cored wire settings The indicator settings for these larger wire sizes are accurate enough so that there is no need to re adjust unless the electrode is unusually soft When using 7 64 2 8 mm diameter Innershield wire adjust the idle roll pressure so that the indicator is between the 120 and 3 32 setting For Aluminum Wire the idle roll pressure should be adjusted as follows a With low idle roll pressure load the feeder so it s ready for welding b Run the feeder at a slow speed about 100 IPM and reduce the idle roll pressure until the idle roll stops rotating c Slowly increase idle roll pressure until the idle roll just starts to rotate consistently with the drive roll without slippage then add an extra 1 4 to 1 3 turn more idle roll pressure This pressure setting should be optimum for feeding and to avoid bird nesting by allowing the drive roll to slip on the wire if a gun cable jam or stoppage occurs If using harder or larger diameter aluminum wires more idle ro
180. rode through the gun If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a bird nest Adjust the brake tension with the hex head screw or thumb screw on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped WARNING The electrode is hot to ground while inching with the gun trigger NOTE On Codes above 7980 the Trigger Interlock and Hot Cold Wire Feed Switch should be in the center position In this position the wire may be fed electrically cold In order to use the new 30 pound Readi Reel electrode package a K363 P adapter is used in conjunction with the K162 H Spindle Kit The K363 P consists of a one piece lightweight reusable molded plastic adapter It is held by securely tightening the K162 H retaining collar The Readi Reel plus the K363 P adapter can also be used on other 2 inch diameter shafts capable of using 30 pound spooled wire An 517712 Installation Instruction is shipped with the kit WARNING The electrode is hot to ground while inching with the gun trigger NOTE On Codes above 7980 the Trigger Interlock and Hot Cold Wire Feed Switch should be in the center position In this position the wire may be fed electrically cold January 1989 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N4 4 12 THREADING ELECTRODE INTO MACHINE 1 When using Models
181. roll wear The Lincoln Electric Company Cleveland Ohio 44117 1199 INCOMING TENSION ADJUSTMENT SCREW QUICK RELEASE PINS In most applications the front and rear drive roll pressures should be adjusted the same To adjust start by releasing both guick release arms Tighten the tension adjusting screws to full pressure and then back off per the particular instructions for your electrode size and type as outlined below For Steel Wire a 030 052 0 8 1 4 mm solid 4 turns from maximum 045 052 1 0 1 4 mm cored 12 turns from maximum The optimum pressure setting can be determined when there are wire stoppages If the wire birdnests between the rolls and guide tubes the pressure is too great When properly set during a stoppage the drive rolls will slip and if the electrode is removed from the cable there will be a slight waviness in the electrode for about a foot beyond the slip marks on the electrode If there is no waviness the pressure is too low b 1 16 1 6 mm solid 2 to 4 turns from maximum 062 1 6 mm cored 7 to 8 turns from maximum The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 2 4 continued These settings should be accurate unless the electrode is unusually soft or the feeding path is excessively long and curved 068 3 32 solid 1 7 2 4 mm 8 to 10 turns from maximum 068 120 cored 1 7 3 0 mm 6 or 7 turns from maximum
182. rough the output shaft opening Do not put grease through the motor mounting side Use about 0 6 of a cubic inch of grease This is a pad 1 2 inch 12 7 mm in diameter by 3 inches 76 2 mm long Replace the output shaft assembly With a wire or screwdriver work the grease around the input worm gear to apply a thin coat of grease to this gear Replace the motor assembly Check the travel motor brushes every three months March 1979 Sec N5 5 7 CIRCUIT PROTECTION AND AUTOMATIC SHUTDOWN 1 Circuit Breaker The circuit breaker located on the front of the LN 9 normally trips only when an overload occurs because of excessive loading in the wire feed cable or a defective motor or control component After allowing a minute for cooling push the reset button and weld If it trips again be sure the wire feed cable is clean and the proper size for the wire diameter being fed If it still trips look for a defective electrical component When the circuit breaker is tripped the digital meter is off and the trigger circuit will not operate 2 Motor Thermal Protection The temperature sensing thermal protector mounted in the motor opens the control circuit if the motor overheats because of excessive loading or freguent triggering This protects the motor without nuisance tripping The thermal protector automatically resets itself after the motor cools sufficiently may take 10 15 minutes Reset time can be shortened by removing supply power to t
183. rs Sec N5 5 5 Hand Travel Unit ne na cha lites a n Y UN nea De Sec N5 5 6 C rcuib Protection ns it re pe vea Het ttti tne fecto fete RT a M AAA YNN Sec N5 5 7 1 Circuit Breaker 2 Motor Thermal Protection 3 Field Circuit Fuse 4 Grounding Lead Protector 5 Voltage P C Board Fuse 6 Automatic Shutdown Sec N6 Maintenance of Gun and Cable Assemblies Submerged Arc Guns Disassembly of Submerged Arc Sguirtguns K113 and K112 III Sec N6 2 1 Disassembly of Submerged Arc Sguirtgun K114 Lesser teret teen tnter Sec N6 2 2 Gun Cable Cleaning DF e beenden drin Yd ten ecd Sec N6 2 3 Gun Nozzles 4o oett e rope Sec N6 2 4 Innershield Guns Disassembly of K126 K115 K264 K345 K355 and K361 SQUITIBUNS EN Sec N6 2 5 Disassembly of K116 Squirtguns retiro tete tette Sec N6 2 6 Gun Cables anu ad gd GW ODD en oe dg GY GN Sec N6 2 7 Gn eidd dee etti iet ts deter etri te eh bd D RID RE Sec N62 8 Lan onditionet Guns cec pti eerie A FFAN Sec N6 2 9 Sec N6 5 Troubleshooting 1 LN 9 General Troubleshooting ane three AO Cb E tte rudera eng d Sec N6 6 2 Comprehensive LN 9 Troubleshooting Guide not included in IM294 en Sec N6 6 1 3 Out of Range Shutdown Sec N6 6 2 Sec N7 Parts L
184. s a dual function In the center position the wire may be fed electrically cold In the down position the wire is electrically hot when feeding and the trigger circuit is controlled only by the trigger In the up position the wire is electrically hot when feeding and the trigger circuit remains energized once the arc is established without holding the trigger until the arc is broken 5 Electrode Hot When Feeding Electrode Cold When Feeding below Code 7981 This switch is found only on the LN 9F and is used to allow electrically cold wire feeding when reguired 6 Wire Feed Direction Switch above Code 7980 Provides wire feed in both directions for easier service 7 Polarity Switch This switch is for circuit control monitoring and is to be set the same as the electrode polarity It does not change the output polarity 8 Volts Wire Speed Switch This switch is used to allow either voltage or wire feed speed to be read from the same meter Assembly and Installation Sec N2 3 2 continue 9 Actual Value Push Button This button us used to allow the meter to be changed from a preset readout to a reading of actual arc voltage or wire feed speed 10 Direct Work Lead Jack below code 8200 This jack permits connection of the direct work clip lead to the LN 9 to more accurately monitor arc voltage See Sec N4 4 4 for direct work lead connection of later LN 9 models 11 Duty Cycle The amount of welding performed
185. s en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high guality welding eguipment consumables and cutting eguip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of
186. s extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 9 s which have a direct work lead jack N D Tape up bolted connection Connect the LN 8 or LN 9 control cable ground lead to the frame terminal marked 77 near the power source terminal strip The power source must be properly grounded N F If using an older LN 8 control cable connect lead 75 to 75 on terminal strip connect lead 76 to 76 on terminal strip connect lead 77 to 77 on terminal strip N G The LN 9 voltage control jumpers must be connected as follows refer to LN 9 Operating Manual White jumper on voltage board to pin S Blue jumper on voltage board later units only or on start board earlier units to pin B N H For DC 600 codes below 8200 Connect a jumper from N to P on LN 9 only Connect a jumper from N to S on LN 8 only There s no NPS terminal strip on codes above 8200 For NR 203 and NR 302 Electrodes 1 Set mode switch to CV Innershield 2 White lead on Control P C Board is connected to Pin I and blue lead is connected to S Codes 8046 8200 For Sub Arc 1 Set mode switch to CV sub arc 2 White lead on Control P C Board is connected to Pin For all Open Arc Processes Except NR 203 Electrodes 1 Set mode switch to CV Innershield 2 ee lead on Control P C Board is connected to Pin
187. s must be of proper capacity for the current and duty cycle of immediate and future applications Connection shown for positive polarity For negative polarity reverse electrode and work cables connected to power source output studs on R3S welders On SAM welders electrode polarity is set by polarity switch on power source Connect the control cable ground lead to the frame terminal marked 77 near the power source terminal strip or to an unpainted frame screw The power source must be properly grounded Use 14 or larger wire physically suitable for the installation and connect it directly to the work piece keeping it separate from the welding work lead circuit and connection Bolt and tape connection M13702 9 22 18 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N2 3 3 N K317 DUAL PROCESS KiT DC 600 CONNECTION TO LN 8 OR LN 9 Welder control cable process kit z EIU To negative To positive output stud on Output stud ori power source power source et N B Wire feeder control cable To work U To A wire feeder To B wire feeder K317 DUAL PROCESS KIT DC 400 CONNECTION TO LN 8 OR LN 9 1 1 To negative LI Welder control cable E Dual process kit db D Em ollo x 215 o 32 iko 1 ai pose joile ai ve To positive output stud on power source 1 output stud on power source
188. s taped to the gun cables make certain it is done in such a manner as to not deform or collapse the flux hose October 1991 Sec N22 8 INSTALLATION OF THE LN 9F AND LN 9FH obsolete 1 Wire Feed Mechanism Mount the wire feed mechanism by means of the mounting plate attached to the bottom of the gear box See L6022 2 Roll or L8505 4 Roll for size and location of the mounting holes The gear box assembly is electrically hot when the gun trigger is pressed Therefore make certain the gear box does not come in 910c Assembly and Installation contact with the structure on which the mechanism is mounted The mechanism should be mounted so that the drive rolls are in a vertical plane so dirt will not collect in the drive roll area Position the mechanism so it will point down at about a 45 angle so the wire feed cable will not be bent sharply as it comes from the unit Install the drive rolls per Section N2 2 2 Wire Feed Rolls and Guide Tubes Control Box a The control has two keyhole slots and one slot for mounting See M13660 for size and location of these holes Mount the box at some convenient location near enough to the wire feed mechanism so that the 16 foot control cables supplied with the LN 9F will reach between the two units Drill the reguired holes in the mounting surface Partially install the 1 4 20 screws Open the control box door Mount the box Tighten the screws C
189. se the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following eguipment Semiautomatic DC Constant Voltage Wire Welder DC Manual S
190. source must be off when changing polarity Bolt and tape connection N B Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications N C Extend lead 21 using 14 or larger insulated wire physically suitable for the installation An S16586 remote voltage sensing work lead is available for this purpose Connect it directly to the work piece keeping it electrically separate from the welding work lead circuit and connection For conve nience this extended 21 lead should be taped to the welding work lead This extended 21 lead connection replaces the need to employ the remote work lead accessory on LN 9 s meter kits which have a direct work lead jack N D The LN 9 Voltage Control jumper must be connected as follows Refer to LN 9 Operating Manual White jumper on voltage board To Pin F for open arc processes or to Pin S for submerged arc processes Blue jumper on voltage board later units only or on start board earlier units to Pin A pp NConnect to desired To LN 9 Input a i2 electrode terminal cable plug N D N A amp N C LN 9 Control cable Work terminal d ss gt Electrode N B cable to to work LN 9 Connect the control cable ground lead to the frame terminal marked 7 the power source terminal strip or to an unpainted frame screw The power source must be properly grounded using an older LN 8 co
191. t AC auxiliary equipment leads to 4 and 31 on the power source terminal strip The auxiliary equipment power requirements should not exceed 15 watts This alternate connection cannot be used with the DC 250 CV or CVI type power source Back panel of the LN 9F without K202 Note space at top of panel and location of connection plug to be used Jumper plug is removed when connecting the K202 kit 4 OR Wi NNNM m 14 R Back panel of the LN 9F with K202 October 1991 The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N3 3 5 M11514 WIRE REEL ENCLOSURE DOOR For N or S Models The door kit includes a hinged door and a sliding bottom seal When installed the wire reel mounting becomes a completely enclosed housing Instructions are included in the kit Put the bottom seal panel in the forward position when using 030 thru 1 16 0 8 thru 1 6 mm electrode and in the rear position when using 5 64 thru 120 2 0 thru 3 0 mm electrode October 1991 Sec N3 3 6 AUXILIARY EQUIPMENT CONTACTS The power for 115 volt AC auxiliary equipment can be obtained from the terminals inside the LN 9 control box The contacts are hot whenever the trigger is pressed or the unit is welding The current draw of this circuit must not exceed 1 4 ampere To use turn the Power Source Off LN 9 or LN 9H Models Install 1 4 6 0 mm quick connect terminals to the leads from the
192. t cable plug Control cable Power source oho D o a o o 9 0 8 Work Work e Electrode cable to wire feed unit To work Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source and properly set the feeder polarity switch NOTE For proper pulse welding operation with LN 9 1 The LN 9 must have an L6084 3 or higher superseding part number voltage board installed Standard above code 9100 2 The Pulse Power Filter board must be installed and connected in the LN 9 per instructions provided with the kit 3 The pulse current sensor assembly with looped copper energizer must be installed Standard above code9100 Feeder conversion kits are available for all LN 9 model codes below 9100 and above 9100 See instruction manual M15205 11 13 87K CONNECTION OF LN 9 TO DC 1000 To LN 9 input cable plug NF Control cable Power source s n A 23818799957 214 2 81321178 74 75 76 77 4 1 Negative Electrode gt cable to wire feed unit Connect to work Above diagram shows electrode connected positive To change polarity turn power off reverse the electrode and work leads at the power source position the positive negative switch on the power source to correspond to the polarity of the electrode cable connectio
193. tage and current increase On some fillet welds a drag technique without the travel unit is used In this instance the amount of flux is controlled by the internal diameter of the nozzle flux cone For sufficient flux on some applications use the nozzle flux cones with larger I D Travel Speed Set the speed of travel with the rheostat on the mechanized travel unit Speed range is 7 to 60 inches per minute 0 2 to 1 5 m min but will vary with AC input variations Operate the toggle switch on the unit to change direction of travel The Lincoln Electric Company Cleveland Ohio 44117 1199 The K161 Power Pack has a pod which is mounted to the front of the LN 8 and LN 9 To set an exact travel speed turn the switch on the pod or the Weld Travel Only switch on LN 4 or ML 3 machines to on or to Travel Only This turns the travel motor on without energizing the welding circuit Adjust the speed dial until you have the exact speed set Return this switch to the off position and you are ready to weld NOTICE Be sure this switch is set on off when plugging in the travel motor or conductor cables Figure 3 Butt Weld Arrow shows direction of travel Position the gun over the seam so the electrode feeds directly into the seam and the gun nozzle is perpendicular to the plate Swing the gun handle horizontally to a comfortable position for welding Be sure the travel drive wheel is parallel to the seam Op
194. tage while welding the automatic shutdown circuit will activate This protection circuit immediately returns the LN 9 control to idle state within a few seconds after the arc voltage discrepancy occurs Typical causes for the activation of this protective shutdown circuit are as follows a SET value of arc voltage is outside the power source range see Out of Range Shutdown in Sec N6 6 2 b Power source voltage control not set for Remote c Misconnection of LN 9 control cable leads to power source d Incorrect weld polarity connections or settings at LN 9 or power source e Lost connection of LN 9 voltage sensing leads 67 and 21 between arc and voltage control or a blown 1 8A fuse on Voltage P C boards built since early 1983 In the case of full range control power sources such as the DC 600 this protective shutdown circuit could prevent welding under the conditions of c d and e above by holding the power source output at minimum possibly providing too low of a power source output to even establish an arc The Lincoln Electric Company Cleveland Ohio 44117 1199 Sec N5 5 7 continued 910c A Circuit Polarity Switch B Direction of Wire Feed Switch C Circult Breaker D G LP Reset E Trigger Interlock and Hot Cold Wire Feed Switch Strap design has changed in later models Maintenance Avoiding Shutdown by the Grounding Lead Protector Being Activated 1 D
195. tick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ug ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant 54 LINCOLN 8 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable
196. ual Process Kits to Wire Feeder Sec N3 Optional Features K178 1 Mounting Platform LN 9N and 9HN on Idealarc R3S or DC 600 nee Sec N3 3 1 K162 H 10 25 Pound Spool Spindle vi is oet d dud d rei Ptr FYD Sec N3 3 2 K163 Undercarriage all LN 9 Wire reel stand combinations sereine Sec N3 33 K202 B rnback Kit OR om Recien oe aba EO en Sec N3 3 4 M11514 Wire Reel Enclosure Door N or S Models eese Sec N33 5 Auxiliary Equipment Contacts Sec N3 3 6 K62 Squirtmoblle aeu ee FY ec ee nr eere ee eee Sec N3 37 K161 Mechanized Travel Power Pack Sec N3 3 8 K70 Filet GU ide au crt rr hee emer eed fro Medd he Sec N3 3 9 K320 Continuous Flux Feeding Tank Assembly Sec 3 3 10 K 35 pA ox Gi tons er seo Leben re nam dde ciuis ol pea pv t N33 11 Vibrate d Screen om edet e e ar tenen wn is GN Persa WY N3 3 12 K299 Wire Reel Assembly en te toe art vtero N33 14 K376 Wire Reel Assembly mere midi ee drea rn Ferre n ER Peri ru cere repe Page eee ra red 3 3 15 K303 Wire Ree Assembly nui Matin iret oa come Pe trit tereti e oreet N33 16 K304 Wire R el Assembly N33 17 K3TT Wire Reel N33 18 K378 Wire Reel Assembly N33 19 K305 Wire
197. ur in J YOUMS 3779 QN 9522 Y gt 205 gt va gt QNO 7 peog dop Si 10 5auuoo pue SI 20 29uuoo adunp reuondo pieog yorquing LES Jayeasg unono liit anve ae 4 HHII 1 rz E 40 0e1u09 peuondo vu Lo 2 7006 Eki lejsoouH 129 L SICA 9314 Mo 1523 dV 8 1 n peods ei 4 5 A YONMAS paeds s oA 8 01 11 6614 1 machines covered by this manual The specific diagram for a ticular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department NOTE This diagram is for reference only It is not accurate for ail for a replacement Give the welder code number L 7200 Dimension Print 19quinu oy Muouiaogjdau 10 juauiuedog 92JAI9S O SI ou j sjaued aunsojoua au JO uo apjsu pojsed 51 ejnojued 10 oj20ds ay 14 Aq Pp919409 ye 10 9184n298 jou 1 19994 10 141 J LON LINN 93
198. used the drive rolls and guide tubes will have to be changed For Steel Wire the idle roll pressure should be adjusted as follows a For wire sizes from 030 thru 052 8 thru 1 3 mm with wire in the system the idle roll pressure indicator The Lincoln Electric Company Cleveland Ohio 44117 1199 should be set to the proper wire size shown on the solid side of the nameplate This setting is a starting point and may have to be changed depending upon type of wire surface condition lubrication and hardness The optimum idle roll setting can be determined when there are wire stoppages If the wire bird nests between the drive roll and the guide tube the idle roll spring pressure is set too high When set during a stoppage the drive rolis will slip and if the electrode is removed from the cable there will be a slight waviness in the electrode for about a foot beyond the slip marks on the electrode If there is no waviness the pressure is set too low a 2 For 030 8 mm wire size if the 030 mark is not present set the pressure indicator slightly less than the 035 marking b For 1 16 solid or 062 1 6 mm cored using the 1 16 drive roll the idle roll pressure should be set with wire in the system For 1 16 1 6 mm solid the indicator should be lined up with the solid 1 16 mark For 062 1 6 mm cored the indicator should be lined up with the cored 062 3 32 common ma
199. y Includes L5027 B 1 Amphenol Connector Female S12020 8 1 Amphenol Connector Male S12024 2 1 Electrode Cable Assembly L5027 C 1 LN 6NE amp LN 6SE Extension Cable Assembly Includes M11518 1 Control Cable Assembly Includes M11517 1 Amphenol Connector Female S12020 11 1 Amphenol Connector Male S12023 3 1 Amphenol Connector Clamp S12024 2 2 Conductor Cable Assembly L4702 1 LN 8NE 8SE 9NE amp 9SE Extension Cable Assembly Includes M12220 1 Control Cable Assembly Includes M12219 1 Amphenol Connector Female S12020 8 1 Amphenol Connector Male S12023 2 1 Amphenol Connector Clamp S12024 2 2 Conductor Cable Assembly L4702 1 Flux Hose 22 1 2 Ft Req d For All Submerged Arc Machines T10642 82 9 1 Flux Hose 45 Ft Req d For All Submerged Arc Machines T10642 83 1 Electrode Cable 22 1 2 Ft Req d On All Machines Above 450 Amps M5906 106 1 Electrode Cable 45 Ft Req d On All Machines Above 450 Amps M5906 104 1 Specify Cable Length and Maximum Current Draw Thru Cable Specify 22 1 2 Ft or 45 Ft as appropriate Q This part is obsolete and no longer available 07 26 2005 P 107 O P 107 O 50 AND 6077 WIRE REEL SUPPORT L4699 07 26 2005 P 107 0 1 Indicates a Change This Printing P 107 0 1 For LN 6N 65 7 8N 8S 9HN and 9S K303 Wire Reel Open Shroud use Column 1 For Enclosed LN 6NE 8NE and 9SE use Column 2 For LN 7 K376 Wire Re
200. ystem in case the plant air has water and dirt in it K310 Flux Screen Optional The unit was designed to fit the top of either the standard fill funnel of a continuous flux feed system or a K58 magnetic separator The unit has a steel screen with 065 to 075 openings and an air vibrator attached to the frame The vibrator can be used with air line pressure ranging from 20 thru 100 psi 138 thru 689 kPa For ease of handling the user should connect the incoming air line to the 1 8 3 2 mm pipe elbow with the aid of a fast disconnect type air coupling It is very important that reclaimed flux to be used in the continuous flux feeding system pass through the K310 screen or its equivalent Magnetic Separator Optional The K58 is a permanent magnet type of separator designed to fit the top of the standard fill funnel of the continuous flux feed system 910c separator The separator is designed so 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 flow When the flux flow stops remove the separator from the funnel or hopper Turn it over and open the panel that covers the magnets Remove the magnetic particles with brushing or an air blast Be careful to protect yourself and others in the area from flying particles The magnetic separator is used with all Lincoln mild steel fluxes 760 7

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