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Lincoln Electric LF-72 User's Manual

1. Section A Technical Specifications sisi A 1 oae EE A 2 Beie A 2 yes 2 Bench Mount ERROR RR A 3 A 3 BOOM MOUN A 3 3 Weld Cable Sizes cc ccccesecsccescedcadecesscesdsnconesccsesensecsscaseeeesesecceseneseeccccsssaeeesccessees A 4 Weld a duc A 5 Weld Cable Connections sise A 5 Analog Control Cable EE A 6 Analog Miller Control Cable Adapter n0000nnnnnnn0nnnnennennnnnnnnnnnnnnnnsennnnnennnnrnnnsnnnnreeennne A 7 Welding Gun Wire Feeder Trigger Connector A 8 High Frequency Protection sise A 8 Remote Sense Lead SpecifiCAtiOns sisi A 8 Wire Drive nennen A 8 Welding Guns Torches and Accessories A 9 Procedure for Changing Drive and Idle Roll A 10 Wire Drive CO OHNO AUG a a ann a A 10 A 11 Pressure Arm Adjustment sise A 11 Wire Reel MO AGING ES cerns eee eue a bee ce a ea er P A 12 Weld Wire Routing sise A 13 Shielding Gas elo lee A 14 Installing Electrode Conduit Kits A 15 Aluminum Wire 1 E A 16 Base Model Bench Model Standard Duty and Bench Model Heavy Duty A 17 Typical System Conigurall ONS 18 OPS EE E
2. Section 1 RS a B 1 EI Nee ee E B 1 Common Welding ele Ee e E B 2 mise TS T T ESTY B 2 Recommended Processes and Required Eoupment B 2 Front Panel Controls and Connections B 3 1 Remote Voltage Control Kit nnn B 4 2 Burnback and Timer Kit Optional B 4 3 Thermal LED Motor Overload ee de doc ce B 4 4 Cold Feed Gas Purge Switch B 4 5 2 Step Trigger Interlock Switch EE B 4 B 5 6 Wire Feed Speed Knob Re B 5 CF ee B 5 8 Trigger Connector 5 Pin Amphenol B 5 ACCESS OMS ers AE des seemed sin et Section C General Options and Accessories C 1 Thru C4 vii Page TABLE OF CONTENTS ET E mente Section D PE CAUTOMS EE EE D 1 Routine e TAIN G Cis ____0_ D 1 Periodic Maintenance ee ee ee en ie nn D 1 Calibration SSS e Lei el D 1 Maj r Component seii eee en on D 2 Troubleshooting SR c Section E Salety 5 1 How Use Troubleshooting Gude E 1 Troubleshooting Guides EE E 2 E 3 Wiring Diagram and Dimension Prints Section F d a P 501 and P 622 LF 72 LINCOLN vii d INSTALLATION A 1
3. 27 amp HEze g OF lui ad ore ghali bis Je d ui Turn power off before servicing Desconectar el cable de ali mentacion de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas X7TTL2A 4 UAUCRU EFBRBAL F4 9 e e SHA AHS Aj lil uiu Juill ail e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes e opere com os paineis abertos ou guardas removidas NAWPAN eRYHLEEE e RE ARE maol Yel 4 OAL h Yi cils gall lia Jedi y e ale WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO FIR Chinese LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR CRU OX
4. S 91 199 9d lt En viss IN 8165 lt C 229 L lt z lt M Les 8299 RT XOoguv3o 18010 tld ES GION310S 0834 Sv5 NOLLO3NNOO ayo AT eT 19 241 I gas 2040419313 LNdNI a or ae 0 00 0 0 09r day H 0000000 guor 3LIHM M a xovg g I faz z 3009 40109 000 op OO olg gtr 16 O d JO 3 5 JFONANOAS ONIYSAEWON ALIAVO LEZEL 0LZLE 60 11 80411 60911 809LL ZO9LE 90911 3409 414124 27 31 HOS WVH5VIG ONIHIM F 5 DIMENSION PRINTS F 5 BENCH MODEL BENCH MODEL STANDARD DUTY 1259 109 28 8 28 LF 72 LINCOLN F 6 DIMENSION PRINTS BENCH MODEL HEAVY DUTY 13 00 He 13 15 F 6 j 12 90 rT LF 72 LINCOLN 27 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese FIR Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja da e Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact av
5. Flux Core Arc Welding PRODUCT DESCRIPTION General Physical Description The LF 72 is optimized for 035 through 045 0 9mm through 1 2mm GMAW welding The powerful 2 roll drive heavy duty enclosure and wire reel stand com bine to make an easy to install easy to use wire feed er for everyday welding Powering the wire drive is a high performance motor gearbox A heavy duty hinged door opens easily which provides an ample amount of room for assembling precision drive com ponents and the welding gun Also under the door is a convenient storage tray for contact tips and tools Three packages are available The basic unit consists of the wire drive box housing The standard duty bench model targets users of 12 305 mm diameter spools The heavy duty bench model satisfies the needs of customers using 60 Ib 27 2 kg spools General Functional Description The LF 72 is a highly versatile and economical choice of industrial feeders Easy to use features are a calibrated WFS knob cold feed gas purge switch and trigger interlock Several kits are available to expand the LF 72 s welding capability The timer kit allows adjustment of burnback and postflow times The remote voltage control kit includes a 0 to 10 dial for setting the weld ing voltage at the wire feeder The swivel kit mounts to the lift bail of a power source and lets the feeder freely rotate so the gun cable stays straight RECOMMENDED PROCESSES GMAW 0
6. JO Si SIU LON F 3 V ON OI LON 9 TN dalSc WN 134908 ds Qv313LIHM SN31 051 40 3903 1 14 HI LS38V3N ON zs HOLIMS 30 39 NOLLO3NNOO 689 9 d NMOHS SYSLAWOILNALOd ANY SSHOLIMS 319901 tir er HOLO3NNOO MOOTHALNI 55 C 0 0 30 3815 WOH SV 39N30038 9NIYIAWNN ALIAVO ON LLLLLLLLLLLLLLLL OC JO ON 9LGLYLELCLILOL 6 8 29 S e C 9 9LSLHLELCLILOL 6 8 Z 3ais LN3NOdWOO Q3N3lA Sv 39Nano3s ONIHASNNN ALIAVO Svo f SALON 666 S ess veSs 799 299 aN 689 109 ess zes 055 oec N ror 9995 96 6 119 Ly n L a E DIE WWYSHL pej sur v 4 HER 099 557 LF 72 LINCOLN amp THESES eg DIAGRAMS 8299 819 IVNOLLdO TTTTTTTT emeng Xoguv3 MSIL S MO14 LSOd ess b 0334 lt lt 169 1 lt lt 1 e NOILOANNODO 318VO 19 lc 289 ES 2004193713 LNdNI 1 E e lt ES TWNOILdO YALSWOLLNALOd on HET FOVLIOA B 92
7. 72 WIRE FEEDER m For use with machines having Code Numbers 11075 11076 11077 11209 11210 11211 11227 11290 11291 11292 11293 11606 11607 11608 11609 11708 11709 11710 11711 Safety Depends on You Lincoln arc welding and cutting equipment 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 OPER ATE OR REPAIR THIS EQUIP MENT WITHOUT READING THIS MANUAL AND THE SAFE TY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful C US IP21 IEC 60974 5 Hi OPERATOR S MANUAL 180 9001 IT gt M E gt ANSI RAB gt 2 t j QMS a 5 o h S m Accredired by the RvA Quality Program Certified 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 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING 1 CALFORNIAPROPOSITIONGS WARNINGS A 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 canc
8. WIRING DIAGRAM F 2 epoo jueuudinbe eui 10 34 eidelt si ou sjaued y euo uo paysed si epoo 1e norued 5 siy AG paraos eq jou UO 99U919 91 104 SI SIUL 310 V L349068 031 30 3LIHM SN31 031 30 3903 1714 3HL LS38V3N Nid HOLIMS 30 9394 NOILO3NNOO NMOHS SYSLAWOILNSALOd NV S3HOLIMS 319901 HOLO3NNOO 40 2016 Qv31INOM3 GAMAIA SV 39N3no03S SNIH3SINON ALIAVO SN quvoa 40 2016 LNSANOdNIOD SV SONSNDAS ONIYASWNN ALIAVO ON t SALON 4315 7 186 zs 68S er er YOOTYSINI Soe eS oF Ven LAM LA Lilli LE 9191 6 8 Z9O9GVvVECHL e 9GrECHL 9191 21110106 8 419 9722 HH on ON 549 A m ET dn 6SS 699 VcSS GG c9G belts LIL 2 NOWINOO jb n 9 9 96 8 19 Ly n KC OVACV Q331 0109 Du 9 rs me v 3 ug UI Bal ms
9. A OHRBEECRA siet CL CRHORSRMELTE DT FEU 1111 EB ET TE REL ES de BA RE EX FH RS ED ECKE 0 SSE FAM HUA EF SAIT Buc veel 91 Clabes Al Jub dolls gail Sall balai agil gaat L LINCOLN E e 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
10. OL Oc cO LO O OH GO OMOD pO OM FO OE er MILLER POWER SOURCE LINCOLN WIRE FEEDER Pin Function Function A 24 VAC to feeder 42 VAC feeder Welding Output Control Welding Output Control ding Output Control B E Remote Voltage Control supply from power source G Remote Voltage Control supply from power source 0 10VDC from feeder for remote control Remote Voltage Control control signal from feeder or remote F Current feedback to feeder Reserved for future use Scaled 0 10V 1 V 100 amps Referenced to pin D J G 24 VAC common K 42 VAC to feeder H Arc Voltage feedback to feeder L Reserved for future use Scaled 0 10V 1 V 10 Arc volts Referenced to pin D N Electrode voltage to power source 67 M Miller is a registered trademark not owned or licensed by The Lincoln Electric Company LF 72 LINCOLN A 8 WELDING GUN WIRE FEEDER TRIGGER CONNECTOR Wire Feeder Amphenol Welding Gun Trigger Lead Wire Feeder Gun Trigger B ___ ____ HIGH FREQUENCY PROTECTION Locate the LF 72 away from radio controlled machin ery The normal operation of the LF 72 may adverse ly affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment INSTALLATION A 8 REMOTE SENSE LEAD SPECIFICATIONS Refer to the power source instruction manual for instructions for connecting the
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12. effects which are now not known All welders should use 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 4 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 6 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 equipment Semia
13. long Magnum 400 gun and cable Figure A 3a with a 15 ft 4 6m long Magnum Pro 350 gun and cable 1 Turn off power at the welding power source 2 Unscrew Thumb screw on Wire Drive Unit until tip of screw no longer protrudes into gun bushing hole as seen from the front of machine Figure A 3 FIGURE A 3 for Codes 11075 11076 11077 11209 11210 11211 11227 11290 11291 11292 11293 LF 72 BASE MODEL A AA GUN RECEIVER BUSHING 7 INTERCHANGABLE LWIRE DRIVE UNIT GUN HANDLE GUNTUBE GUN NOZZLE GUN AND CABLE GUN TRIGGER CONNECTOR _ CABLE CONNECTOR END K466 10 INSTALLATION A 9 3 Fully insert the gun cable connector end into the gun receiver bushing and gently tighten the thumb screw as show in Figure A 5 4 Connect the gun trigger connector to the trigger receptacle Make sure that the key ways are aligned and insert Figure A 3a FIGURE A 3a for Codes 11606 11607 11608 11609 LF 72 BASE MODEL A 2 _ f j D d f j Jj 2 iP la P 9 x i M d Co Le TRIGGER RECEPTACLE C J I GUN RECEIVER BUSHING Xo INTERCHANGABLE E DRIVE UNIT GUN TUBE vd QUNNOZZLE GUN AND CABLE GUN TRIGGER CONNECTOR CABLE CONNECTOR END K466 10 LF 72 LINCOLN A 10 INSTALLATION A 10 PROCEDURE FOR CHANGING WIRE DRIVE CONFIGURATION See
14. olo 9 d NOWINOO ons a dem HOD 9 9 26 6 448 gt N U 085 1 39vi10AOuv zr SE un 52 SIE E Bi III UU D em JJ vi 0371 WWWYSHL EE ine va guy xu LL Br 52 0 5 La all EE E 5 J3OoHnos v909 Bee 3 TONSHdNV or 1 O 9 2298 LS Vly 09 Le dk sc se dk 42 088 Ly CN 01 6829 Sv 2 V 999 Y vv Y v Y 1 m LAAN LL DEG SIE e M 0299 L VN p vlt 809 909 M 9299 209 209 919 109 84 9 111111171 e _ THOLON WNOILdO oor LIM S3IALL yovanuna MOTH LS0d 299 410 3105 Sv9 deeg 4d GN uw NOILOANNOO 31479 19 298 ON 0813 azes IVNOLLdO 7 J9YLI0A 94 92 VOL ne _ 3LOIN3H m SL i VSL aN 9 6 8 iu 9 ogr er ed 50890800 M 9900 er sr u N i 7 JN lt Sr 034 H 9 v 7 6 2 YILINOILNILOd Ka AUHM M 090 VS S I lt lt MOVE g z Jr er TT up a 3009 80109 z 334 SHIM SS VAS M 9 9 26919 S108AAS 1V914193713 JO IN3NOdWOO JONSNOAS ONIHAEUNN ALIAVO 21011 9ZOLL SZOLL Y40334 27731 gy LL
15. welding machines 1 c Do not add the fuel near an open flame 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 Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring 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 Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running A 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
16. Figure A 5 Changing the Gun Receiver Bushing WARNING DRIVE AND IDLE ROLL SETS See Figure A 4 A WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before instal lation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Only qualified personnel should perform mainte nance work 1 Turn power off at the welding power source 2 Release the idle roll pressure arm 3 Remove the outer wire guide by turning the knurled thumbscrews counter clockwise to unscrew them from the feed plate 4 Rotate the triangular lock and remove the drive rolls FIGURE A 4 LOCKED POSITION UNLOCKED POSITION Remove the inner wire guide Insert the new inner wire guide groove side out over the two locating pins in the feed plate Install a drive roll on each hub assembly secure with the triangular lock 8 Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews 9 Close the idle arm and engage the idle roll pres sure arm Adjust the pressure appropriately SEN N CONNECTOR BLOCK ELECTRIC SHOCK can kill e Turn the input power OFF at the dis connect switch or fuse box before attempting to connect or discon ne
17. Power Sources cable for connecting a Lincoln 42 VAC wire feeder to a 24 VAC Miller power source Includes One transformer kit K1520 1 42 Volt Transformer Kit for operating a 42 VAC wire feeder on a power source sup plying only 115 VAC K1798 Adapter Cable for Control Cable to Includes Terminal Strip Power Sources K910 1 Ground Clamp Includes One 300 Amp Ground Clamp Ground Clamp Includes One 500 Amp Ground Clamp Gun Receiver Bushing for guns Includes Gun receiver bush with K466 1 Lincoln gun connec ing set screw and hex key tors Innershield and Subarc guns wrench Gun Receiver Bushing for guns with Includes Gun receiver bush K1500 2 K466 2 K466 10 Lincoln gun con ing with hose nipple set screw standard on nectors Magnum 200 300 400 guns and hex key wrench LF 72 s and compatible with Tweco 4 Gun Receiver Bushing for guns Includes Gun receiver bush K1500 3 with K613 7 Lincoln gun connec ing with hose nipple set screw tors Magnum 550 guns and com and hex key wrench patible with Tweco 5 Gun Receiver Bushing for gun Includes Gun receiver bush K1500 4 with K466 3 Lincoln gun connec ing with hose nipple set screw tors compatible with Miller guns and hex key wrench Includes Gun receiver bush K1500 5 Gun Receiver Bushing compatible ing with hose nipple 4 guide with Oxo guns tubes set screw and hex key wrench LF 72 LINCOLN K4
18. adjustment prevents the wire from sticking to the weld at the end of a weld and helps to condition the wire for the next weld To set the burnback time adjust the knob to approxi mately 0 03 seconds and then decrease or increase the time as desired Postflow Timer The postflow timer range is OFF to 10 seconds Postflow is the time from when the power source out put turns OFF until the postflow timer expires Use postflow to protect the weld while the weld cools 3 THERMAL LED MOTOR OVERLOAD The thermal light illuminates when the wire drive motor draws too much current If the thermal light illu minates the wire drive will automatically shutdown for up to 30 seconds to allow the motor to cool To start welding again release the gun trigger inspect the gun cable liner and conduit Clean and make repairs aS necessary Start welding again when the problem has been safely resolved For best results keep the gun cable and conduit as straight as possible Perform regular maintenance and cleaning on the gun liner conduit and gun Always use quality electrode such as L 50 or L 56 from Lincoln Electric 4 COLD FEED GAS PURGE SWITCH Cold Feed and Gas Purge are combined into a single spring centered toggle switch COLD FEED To activate Cold Feeding hold the switch in the UP position The wire drive will feed electrode but neither the power source nor the gas solenoid will be ener gized Adjust the speed of cold feedin
19. degreasing cleaning or spraying operations The heat and 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 equipment 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 Jan 09 6 j SAFETY N Z WELDING and CUTTING gt 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 equipment being used When not welding make certain no part of the electrode circuit is touching the work or groun
20. fumes and gases from your breathing zone and general area WELDING SPARKS can cause fire or explosion D Do not weld near flammable material e Do not weld on containers which have held flammable material ARC RAYS can burn Wear eye ear body protection RZ Observe additional guidelines detailed in the beginning of this manual LF 72 The serviceability of a product or structure utilizing the LF 72 wire feeder is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the LF 72 wire feeder These variables include but are not limited to welding procedure plate chemistry and tempera ture weldment design fabrication methods and ser vice requirements The available range of the LF 72 wire feeder may not be suitable for all applications and the builder user is and must be solely responsi ble for welding settings GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL COLD FEED POSITIVE OUTPUT NEGATIVE OUTPUT PROTECTIVE GROUND WARNING OR CAUTION DANGEROUS VOLTAGE J e SHOCK HAZARD WELDING FUMES EXPLOSION GAS INPUT WORK CONNECTION SES LINCOLN B 2 COMMON WELDING ABBREVIATIONS WFS Wire Feed Speed CV Constant Voltage GMAW MIG Gas Metal Arc Welding FCAW Cable Innershield or Outershield
21. rays Protect other nearby personnel with suitable 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 require 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 required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment 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
22. tv JOULNOOD Si i YOLOANNOO 3ounos 4359141 799 O 958 YVINOHIO LNdNI M 8 055 LS Nid vL 83991 A 196 M gt al S 99 9 com TENE 5 gt gt A ion Ola Ne Ela FUE P ua in GaLNNOW v qJ144v8 Pu CONNU incl Se em 29299829 ww SP JUHM M dio c MEE M313AOLLN3LOd 529 g fan z 10 1N09 3905 40109 509 zr OO el Ss 43345 9 9 sf 4884 JHM 18913 Yad ST08WAS 7911997 e 40 AGIS LN3NOdIltOO NOILVWYOANI HONGOS ONIYSEWNNN ALIAVO 26211 26211 16211 06211 58003 804 Y30344 22 51 F 3 DIAGRAMS F 4 F 4 Jequunu epoo jueuudinbe eui 3ueujeoe daJ 201S 34 si ou j sjaued y euo uo paysed epoo 1e norued 10 4 9 siy eq jou j 4315 2 489 e 68S X00 TH31NI H3991HL Sp ON 4334 a31 WWHSHL TN 909 an v909 eir HOLO3NNOO 4399141 vgs O 999 INdNI H3991IHL A V N A I EN 809 v909
23. 23 1 16 0 6 1 6 mm steel electrodes FCAW 035 5 64 0 9 2 0mm cored electrodes OPERATION PROCESS LIMITATIONS B 2 Rated for up to 1 16 1 6 mm solid electrode and 5 64 2 0 mm cored electrode The maximum WFS is 800 in min 20 3 M min The LF 72 is not recommended for GMAW Pulse synergic GTAW GTAW Pulse SAW CAG SMAW Do not use push pull equipment with the LF 72 For K2327 2 5 Bench model std duty Maximum spool size 44 Ib 20 kg 12 inch 300mm diame ter 4 inch 100mm For K2327 3 6 7 Bench model heavy duty Maximum spool size 60 Ib 27 2 kg REQUIRED EQUIPMENT Lincoln s LF 72 is designed for use with the CV and DC family of power sources These include CV 305 DC 400 CV 400 DC 600 e CV 655 e Invertec V350 e Invertec V450 EQUIPMENT LIMITATIONS e Maximum gun length 25 ft 7 6m e Maximum conduit length 30 ft 9 1m e Maximum total control cable length 100ft 31m e The LF 72 operates on 42VAC and not 115 VAC e The K1733 1 wire straightener may not be used with the LF 72 e Gun bushings are required for welding guns that do not have a Magnum Tweco 2 4 compatible back end The LF 72 does not attach to K303 wire reel stands LF 72 LINCOLN B 3 OPERATION B 3 FRONT PANEL CONTROLS AND CONNECTIONS CASE FRONT CONTROLS FIGURE B 1 AL N ITEM DESCRIPTION Location for Optional Remote Voltage Cont
24. 3 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES 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 Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilacion o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a e Use ventilac o e exhaust o para remover fumo da zona respirat ria VE E EE KE UE FEU RAR BEES e OF OF JL EX 422374 24752 Beleg z37r 8 218 71
25. 466 2 K466 10 Lincoln gun connectors Magnum 200 300 400 guns and compatible with Tweco 4 K1637 7 Lincoln gun connectors Magnum 550 guns and compatible with Tweco 5 K1500 3 K1500 4 K466 3 Lincoln gun connectors compatible with Miller guns K1500 5 Compatible with Oxo guns K489 7 Lincoln Fast Mate guns INSTALLATION PRESSURE ARM ADJUSTMENT AA WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before instal lation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Only qualified personnel should perform mainte nance work The pressure arm controls the amount of force the drive rolls exert on the wire Proper adjustment of the pressure arm gives the best welding performance Set the pressure arm as follows See Figure A 6 Aluminum wires between 1 and 3 Cored wires between 3 and 4 Steel Stainless wires between 4 and 6 FIGURE A 6 CORED WIRES SOLID WRES ALUMINUM STEEL STAINLE SS OUTERSHIELD METAL SHIELD INNERS HIELD LF 72 LINCOLN A 12 WIRE REEL LOADING AA WARNING hands hair clothing and tools away from rotating equipment e Do not wear gloves when threading wir
26. 89 7 K466 2 K613 7 K1546 1 K1546 2 K435 K468 K363P K438 K1504 1 ACCESSORIES OPTIONAL KITS Gun Receiver Bushing for Lincoln Includes Gun receiver bush Fast Mate guns ing with trigger connector Magnum 200 300 400 to K1500 2 Includes Gun adapter cotter Adapter pin hex key wrench wrench Magnum 550 to K1500 3 Adapter Includes Trigger adapter gun Lincoln Conduit adapter and hex key wrench Incoming Bushing for Lincoln Includes Incoming bushing Conduit 025 1 16 0 6 1 6mm and hex key wrench wire Incoming Bushing for Lincoln Includes Incoming bushing Conduit 1 16 1 8 1 6 3 2 mm and hex key wrench wire Spindle Adapter for mounting 14 Includes Spindle Adapter lb 6 4 kg Innershield Coils on 2 made from 2 coil retainers in 51 mm spindles Spindle Adapter for mounting 203mm diameter spools on 2 in 51 mm spindles Electrode not included 8in Includes Spindle Adapter Readi Reel Adapter for mounting Includes Readi Reel spool 23 30 Ib 10 4 13 6 kg reels to 2 adapter Spool of electrode in 51 mm spindles not included Readi Reel Adapter for mounting Includes Readi Reel spool 50 60 lb 22 7 27 2 kg reels to 2 adapter Spool of electrode in 51 mm spindles For use with not included Heavy Duty Bench models Coil Adapter for mounting 50 Ib 22 7 27 2 kg coils to 2 in mm spindl
27. 8919 109 I L9Svetzc x IYNOLLdO 1 11111177 UN H3INLL XXXIII oae m TN on lt HALAWOILNALOd LT E ADVLIOA wennt 92 qe lt et vo 1031409 3LOWSY SL vs ON HALSWOLLNSLOd Sn 1041409 43345 9 6 9333 T 1 A UO 10 S SIUL 310 qasn LON TN 1349068 031 30 VN Qv313LIHM SN31 031 39493 171 LSSYVAN Nid ON HOLIMS 30 3015 NOILOANNOO NMOHS SH3 L3INOLLN3 LOd S3HOLIMS 319904 Quvoa O d 501VNV NOIWINOO HOLO3NNCO vir er zr 30 395 07371 SV SONSNOAS SNIH3SINON ALIAVO ON CO SS und l Quvoa 40 tL 1444 STEE 441 3015 LN3NOdWOO WCH SV 3ON3N03S ONIHASANN ALIAVO 1 0 6 8 9Grecaet CL 1101 6 E SCH LI SALON GIS 666 3 209 299 9S6 258 799 68S 109 sss 289 Les 96 v wid 8 84 v 4 2 9 ER gt VOL Y 897 WSL 99 gt 19 8 9 HE OH1NOO ASVLIOA 310N3H 7031405 Andino 3ounos OL YOLOANNOO 4v1n9419 7 26919 43 SIOEWAS 1991319573 NOILVINHOJNI TVH3N39 woe S ae 91 9 9 e 9 9 1 851 n 296 LL 596 P
28. LATION A 4 SAFETY PRECAUTION A ELECTRIC SHOCK can kill Only qualified personnel should perform this installation e Turn off the input power to the power source at the disconnect switch or fuse box before work ing on this equipment Turn off the input power to any other equipment connected to the weld ing system at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts WELD CABLE SIZES Table A 1 has the copper cable sizes recommended for different currents and duty cycles Lengths stipu lated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of mini mizing voltage in the welding circuit TABLE A 1 RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 75 C CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES Percent 0 to 50 Ft 50 to 100Ft 100 to 150 Ft 150 to 200 Ft 200 to 250 Ft Duty Amperes 0 to 15m 15 to 31m 31 to 48 m 48 to 61 m 61 to 76 m Tabled values are for operation at ambient temperatures of 40 C and below Applications above 40 C may require cables larger than recommended or cables rated higher than 75 C LF 72 LINCOLN 5 INSTALLATION A 5 COAXIAL WELD CABLES Coaxial welding cables are specially designed welding cables for pulse welding or STT welding Coaxial weld cables feature low inductance allowing f
29. Package Co Axial Power Cable Includes 10k potentiometer harness knob and decal with a 0 10 scale and mounting hardware Includes Panel and harness for adjusting burnback and postflow times Includes Wire Reel Stand for up to 44 Ibs 20 kg spools Spindle and mounting hard ware Includes Insulated lift bail and hardware Includes Swivel adapter and for use with Standard Duty Bench mounting hardware for attach ing to a power source lift bale Includes Coaxial weld cable of length xx Ends of the weld cable have lug connec tions Use for Pulse or STT welding Includes Twist Mate to Lug 2 0 cable 14 1 2m long with Ground Clamp and Twist Mate to Lug 2 0 Cable 9 2 7m long K1840 xx Weld Power Cable Twist Mate to Includes Twist Mate to Lug Lug 1 0 cable of length xx Weld Power Cable Twist Mate to Twist Mate K1841 xx K1842 xx Weld Power Cable Lug to Lug Includes Twist Mate to Twist Mate 1 0 Cable for 25 7 6m cables Includes Twist Mate to Twist Mate 2 0 Cable for 50 15 2m cables Includes Lug to Lug 3 0 Cable of length xx for lengths up to 60 18 3m Lug to Lug 4 0 Cable of length xx for lengths greater than 60 18 3m LF 72 LINCOLN C 2 ACCESSORIES C 2 OPTIONAL KITS Includes 14 pin to 14 pin wire K1797 xx Control Cable feeder to power source control cable Includes Adapter control K2335 1 Adapter for Miller
30. SSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LF 72 LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION OUTPUT PROBLEMS The wire feeder does not feed wire 1 Verify the power source is turned and the drive rolls do not spin on Verify the circuit breaker for the wire feeder on the power source has not tripped Check that the gun trigger is operating properly If the motor thermal LED is illumi nated wait approximately 1 minute before welding again Inspect the gun for feeding prob lems Verify power is being supplied to the wire feeder The wire feeds erratically or the 1 Verify the correct drive rolls and Motor Thermal LED lights inner wire guide are installed in the wire drive Check for sharp bends in the gun liner Examine the contact tip for wearllf all recommended possible areas and proper size Replace as nec misadjustment have been checked essary and the problem persists Contact Check the gun liner The weldinglyour local Lincoln Authorized electrode shou
31. TECHNICAL SPECIFICATIONS LF 72 Wire Feeder WIRE FEED SPEED RANGE Wire Size LF 72 Speed Solid 50 800 IPM 1 27 20 3 m m 023 1 16 in 0 6 1 6 mm 035 5 64 in 0 9 2 0 mm CONTROL BOX WIRE DRIVE AND COMPLETE UNITS SPEC 4 TYPE INPUT POWER PHYSICAL SIZE TEMPERATURE RATING m adip _ and Current Width Depth Weight Operating Storage 26 5 Lbs K2327 1 LF 72 11 1 10 2 12 9 282 259 328 K2327 4 Base Model 12 0 Kg Dimensions Weight LF 72 K2327 2 24 42VAC 52 5 Lbs 14 F to 104 F 40 F to 185 F K2327 5 Bench 9 AMPS 23 8 Kg 10 C to 40 C 40 C to 85 C Standard Duty Dimensions Height Width Depth Weight K2327 3 LF 72 K2327 6 15 3 1347 27 7 67 5 Lbs K2327 7 Bench 389 330 704 mm 30 6 Kg Heavy Duty WELDING CAPACITY RATING Amp Rating Duty Cycle 500 A 60 Dimensions do not include wire reel LF 72 LINCOLN A 2 INSTALLATION A 2 SAFETY PRECAUTION ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn off the input power to the power source at the disconnect switch or fuse box before working on this equipment Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on this equipment Do not touch electrically ho
32. are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LF 72 LINCOLN LL WIRING DIAGRAM F 1 Jequunu epoo jueuudinbe SAIN e 104 uowyedeq ou eidel s y sjeued eunsoJoue y euo uo y paysed epoo 104 4 oul jenueui siy Aq JO eq jou 104 S SIUL LON 9 144905 G31 SNOITV SNF1 51 30 4903 LV14 JHL LS38V3N Nid ON HOLIMS 40 ACIS NOILOANNOO NMOHS SS31L3INOLLN3 LOd NV S3HO9LIMS 319901 O N HOLO3NNOO 30 31 QV31IAO83 SV 39N30038 ONIYAENINN ALIAVO qvO8 40 3015 LN3NOdWOO SV 39N36038S SNIS3SIADN ALIAVO SALON 9315 489 eS 689 vir er er Ir MOO TH3 INI FO ra 44 LLLLLLLLLLLLLLLL 9 91 1 612111006 8 2 9 S v CL c 9GvECHL OLSLVLELZLILOL6 8 499 722 f aN ON SVD TM Ki or 666 3 ap 699 299 VcSS 799 298 ibo esc
33. as flow rate and mix ture Verify the gun bushing is tightly to the wire drive Verify the gun is tightly mounted to the gun bushing The motor thermal LED illuminates Check for sharp bends in the gun liner Examine the contact tip for wear and proper size Replace as nec essary Check the gun liner The all recommended possible areas of electrode should slide easily misadjustment have been checked through the gun and the problem persists Contact Verify the proper gun liner isfyour local Lincoln Authorized installed Field Service Facility Reduce the pressure arm setting On bench models make sure the brake tension is not too tight If using a wire conduit verify the wire slides easily through the conduit Check all electrode and work connections Verify the gun bushing is tightly to the wire drive Verify the gun is tightly mounted to the gun bushing Check the control cable and con nectors for cuts Verify that no pins are broken or bent When the gun trigger is pulled the drive rolls spin but no arc is present The arc burns back to the tip at the 1 If the timer kit is installed reduce end of the weld the amount of burnback time The gas continues to flow for a long 1 If the timer kit is installed reduce time at the end of a weld the amount of postflow time CAUTION If for any reason you do not understand the test procedures or
34. asse le c ble de soudage et la machine souder en bon et s r tat defonctionnement 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 deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 9i 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 c ble lectrode autour de n importe quelle partie 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 du 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
35. ast changes in the weld current Regular cables have a higher inductance which may distort the pulse or STT wave shape Inductance becomes more severe as the weld cables become longer Coaxial weld cables are recommended for all pulse and STT welding especially when the total weld cable length electrode cable work cable exceeds 50 feet 7 6m 9 Cf gt ect rode Coaxial Weld Cable A coaxial weld cable is constructed by 8 small leads wrapped around one large lead The large inner lead connects to the electrode stud on the power source and the electrode connection on the wire feeder The small leads combine together to form the work lead one end attached to the power source and the other end to the work piece See Coaxial weld Cable below WELD CABLE CONNECTION Connect a work lead of sufficient size between the proper output stud on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact Poor work lead connec tions can result in poor welding performance A Wire Feeder Electrode Work LF 72 LINCOLN A 6 INSTALLATION ANALOG CONTROL CABLE CONTROL CABLE CONNECTIONS All control cables can be connected end to end to extend their length The control cable connecting the wire feeder to the power source is specially made for the welding envi ronment The wire feeder power requires overcurrent pr
36. bar Install the shielding gas supply as follows 1 Secure the cylinder to prevent it from falling 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet 4 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench Note If connecting to 100 CO cylinder insert regulator adapter between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated for connection to the CO cylin der INSTALLATION A 14 5 Attach one end of the inlet hose to the outlet fitting of the flow regulator Attach the other end to the welding system shielding gas inlet Tighten the union nuts with a wrench 6 Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released 7 Standing to one side open the cylinder valve slowly a fraction of a turn When the cylinder pressure gage stops moving open the valve fully 8 The flow regulator is adjustable Adjus
37. ch advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of 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 requirements 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 Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently 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 equipment identification information below for future reference This informatio
38. ct input power lines output cables or control cables e Only qualified personnel should perform this installation Tools required e 1 4 hex key wrench Note Some gun bushings do not require the use of the thumb screw 1 Turn power off at the welding power source 2 Remove the welding wire from the wire drive 3 Remove the thumb screw from the wire drive 4 Remove the welding gun from the wire drive 5 Loosen the socket head cap screw that holds the connector bar against the gun bushing Important Do not attempt to completely remove the socket head cap screw 6 Remove the outer wire guide and push the gun bushing out of the wire drive Because of the pre cision fit light tapping may be required to remove the gun bushing FIGURE A 5 THUMB SCREW OUTER WIRE GUIDE SOCKET HEAD CAP SCREW 7 LOOSEN TIGHTEN LF 72 LINCOLN A 11 7 Disconnect the shielding gas hose from the gun bushing if required 8 Connect the shielding gas hose to the new gun bushing if required 9 Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw 11 Insert the welding gun into the gun bushing and tighten the thumb screw Gun Receiver Bushing K1500 1 K466 1 Lincoln gun connectors Innershield and Subarc guns K1500 2 K
39. d Accidental contact can cause overheating and create a fire hazard Do not 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 an
40. d Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged EM 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 e Away from areas where they may be struck or subjected to physical damage eA 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 equipment and CGA publication PL 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 equipment 8 a Tur
41. de grue ou autres circuits Cela peut provoquer des 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 du corps PRECAUTIONS DE SURETE POUR Un coup d arc peut tre plus severe qu un coup de soliel LES MACHINES A SOU DER A E TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se proteger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositi
42. e or changing wire spool Only qualified personnel should install use or service this equipment Loading 10 to 15 Ib 4 5 6 8kg Spools A K468 spindle adapter is required for loading 2 wide spools on 2 51mm spindles Use a K468 1 spindle adapter for loading 2 1 2 64mm wide spools See figure A 7 and figure A 8 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the spindle adapter on the spindle aligning the spindle brake pin with the hole in the adapter 3 Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool An indicator mark on the end of the spindle shows the orientation of the brake tab Be certain the wire feeds off of the spool in the proper direction 4 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle FIGURE A 7 Adapter Spindle Placement The wire reel stand provides two mounting locations for the spindle Each mounting location consists of a tube in the center of the mast and locating slots Loading 16 to 44 Ib 7 3 20kg Spools See figure A 8 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the spool on the spindle aligning the spindle brake pin with one of the holes in the back side of the spool An indicator mark on the end of the spin dle
43. ec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da e terra o ZEPO Pori e E BASURA DERE RR IER SFR CHRARACRHMALF HE CC SHE Ne SA ass SU e HIE Ju At vill el jad ye A ead slay ag A uiu gladly All JIE dus Wile tn e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e RAPT e 18 9 z PR SS AIX Ana Se Ji ALAN 3 gl ave Wear eye ear and body protection e 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 e Use prote o para a vista ouvido e corpo e HRUSHIRBRELTE ez 19 HOTTE AS 52 Asi due Lily ausu y cil gai k 5
44. eeder feeds wire for welding The gun trigger is then released while the weld is made To stop welding the gun trigger is pulled again and when it is released the welding power source output turns off and the wire feeder stops feeding wire CAUTION If the arc goes out while welding with trigger interlock operation the elec trode output from the welding power source remains energized and the wire feeder will continue to feed wire until the gun trigger is again pulled and then released 6 WIRE FEED SPEED KNOB The large calibrated wire feed speed knob makes for easy and accurate adjustment of the wire feed speed The knob rotates 3 4 turn Turn the knob clockwise to increase the wire feed speed and counter clockwise to reduce the wire feed speed The wire feed speed range is 50 to 800 in min 1 27 20 3 m min 7 GUN RECEIVER BUSHING K1500 2 K1500 2 bushing is standard on all LF 72 s This Gun Receiver Bushing is used with Lincoln gun connectors also with Magnum 200 300 400 guns and compatible with Tweco 4 8 TRIGGER CONNECTOR 5 PIN AMPHENOL This is used for connecting the MIG gun trigger See Installation Section for detail LF 72 LINCOLN 1 ACCESSORIES OPTIONAL KITS Remote Voltage Control Kit K2329 1 K2330 1 Timer Kit K2328 1 Standard Duty Wire Reel Stand K2331 1 Lift Bail Kit Swivel Kit Models K2332 1 K1796 xx K1803 1 Work and Feeder Cables
45. er birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 N FOR ENGINE To avoid scalding do not remove the powered equipment d ia pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance 3 work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated XA areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS E Stal bb 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
46. es 60 51 Includes 50 60 Ib 22 7 2 2 kg coil adapter For use with heavy Duty Bench models LF 72 LINCOLN C 3 4 ACCESSORIES OPTIONAL KITS Includes Cover backing K1634 1 Plastic Wire Cover for 30 44 Ib plate wire conduit incoming 13 6 20 0 kg Wire packages bushing for 025 1 16 0 6 For use with Standard Duty 1 6 mm wire incoming bush Bench Models and Heavy Duty ing for 1 16 1 8 1 6 3 2 Bench Models mm wire thumb screw mounting hardware and hex key K1634 2 Plastic Wire Cover for up to 60 Ib 27 2kg Wire packages For use with Heavy Duty Bench Models K659 1 Gas Guard Regulator Includes Gas Guard Regulator and adjustment key Includes Gas Regulator for 3000290 Adjustable Gas Regulator Mixed Gases and 10 3 0m Hose Includes Deluxe Gas K586 1 Deluxe Adjustable Gas Regulator Regulator for Mixed Gases Adapter for CO2 and 10 3 0m Hose K1524 3 Heavy Duty Universal Wire Reel Includes Heavy Duty Wire Stand For spools up to 60 Ib Reel Stand 27 2kg 4 Wheeled Wire Feeder Includes Undercarriage with K163 Undercarriage For use with 8 203mm rear wheels 4 Standard Duty Bench Models and 102mm casters Heavy Duty Bench Models K1557 1 Swivel Platform for use with Includes Swivel Platform and Heavy Duty Bench Models Tray K1556 1 Light Duty Caster Kit for use with Includes 2 Swivel Casters 2 Heavy Duty Bench Models Fixed Casters bracke
47. ew to secure the conduit connec tor in the wire drive 5 Insert conduit through the sheet metal of the LF 72 and into the conduit connector Secure with the thumb screw FIGURE A 11 THUMB SCREW CONDUIT CONNECTOR SR m A We h Ir j Iul VW N Nu LF 72 LINCOLN A 16 ALUMINUM WIRE PREPARATIONS WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the dis connect switch before working on this equipment Do not touch electrically hot parts Welding with aluminum filler wires requires extra care Aluminum wire is softer and not as stiff as steel wires it is important to keep aluminum wire free of dirt and scratches Limit gun length to 10 Ft 3 0 m for best results and use a spool cover if feeding from a spool To prevent scratching of the aluminum wire remove the ball bearings from the ball housing as follows For Codes 11075 11076 11077 Tools required See Figure A 12a Snap Ring Pliers 9 64 Hex key wrench 1 Turn off power at the welding power source 2 Remove the snap ring holding the ball bushing assembly to the back of the wire feeder Remove the ball bushing assembly FIGURE A 12a BALL 3 BUSHING ASSEMBLY INSTALLATION A 16 For Codes 11209 11210 11211 and above Tools required See Figure A 12b 9 64 Hex key wrench 1 Turn off powe
48. f de montage ou la piece souder doit tre branch une bonne mise la terre soudage l aide d crans appropri s et non inflammables 2 Autant que possible l installation et l entretien du poste seront Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres 3 Avant de faires des travaux l interieur de poste la debranch de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN gue effectu s par un lectricien qualifi er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V TABLE OF CONTENTS V A f for selecting a QUALITY product by Lincoln Electric We want you ou 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 quality welding equipment consumables and cutting equip 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 su
49. from the LF 72 See Figure D 1 4 Set WFS Knob to 50 IPM and trigger the machine 5 Measure drive role RPM If reading is 8 9 to 9 2 RPM proceed to step 6 otherwise insert the short ing plug into the control p c board J2 shorts pins 1 and 5 See Figure D 2 and adjust WFS Knob to get 9 05 0 15 RPM and then remove shorting plug LF 72 WRAPAROUND SCREWS 6 Set WFS Knob to 300 IPM 7 Measure drive role RPM If reading is 54 8 to 56 0 RPM proceed to step 8 otherwise insert the short ing plug into the control p c board J2 shorts pins 1 and 5 See Figure D 2 and adjust WFS Knob to get 55 4 0 6 RPM and then remove the shorting plug 8 Set WFS Knob to 800 IPM 9 Measure drive role RPM If reading is 146 4 to 148 4 RPM calibration is complete otherwise insert the shorting plug into the control p c board J2 shorts pins 1 and 5 See Figure D 2 and adjust WFS Knob to get 147 4 1 0 RPM and then remove the shorting plug Release the Gun Trigger connect J2 of the harness to p c board FIGURE D 2 LINCOLN E 1 TROUBLESHOOTING E 1 WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before installation or changing Y e drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is relea
50. g by rotating the WFS knob Cold feeding or cold inching the electrode is useful for threading the electrode through the gun Hold with toggle switch in the DOWN position to acti vate Gas Purge and let the shielding gas flow The gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on The Gas Purge switch is useful for setting the proper flow rate of shielding gas Flow meters should always be adjusted while the shielding gas Is flowing 5 2 STEP TRIGGER INTERLOCK SWITCH The 2 Step Trigger Interlock switch changes the function of the gun trigger 2 Step trigger operation turns welding on and off in direct response to the trigger Trigger Interlock operation allows weld ing to continue when the trigger is released for comfort on long welds Place the toggle switch in the DOWN position for 2 Step operation or in the UP position for Trigger Interlock operation 2 Step Trigger 2 Step trigger operation is the most common When the gun trigger is pulled the welding power source energizes the electrode output and the wire feeder feeds wire for welding The power source and wire feeder continue welding until the trigger is released LF 72 LINCOLN B 5 OPERATION Trigger Interlock Trigger Interlock operation provides for operator com fort when making long welds When the gun trigger is first pulled the welding power source energizes the output and the wire f
51. g spools 035 045 combo LF 7 2 035 045 0 9 1 2 mm 0 9 1 2 mm K2327 3 Bench Model Heavy Duty Heavy Duty up to 60 lb 27 2 kg coils PART NO Description Wire Reel Stand Drive Roll Kit Feeder K2327 5 Bench Model Standard duty up to LF 7 TABLE 2 Standard Duty 2 15 Magnum Pro 350 44 Ib 20 kg spools 035 045 combo 035 045 0 9 1 2 mm 0 9 1 2 mm Heavy Duty up to 60 Ib 27 2 kg coils K2327 6 nd EN K2327 7 eavy Duty LF 72 LINCOLN B 1 OPERATION 1 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine WARNING e ELECTRIC SHOCK can kill e Unless using cold feed feature when feeding with the gun trigger the electrode and drive mechanism are always electrically energized and could remain energized several seconds after welding ceases e Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground e Always wear dry insulating gloves ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR SERVICE THIS EQUIPMENT READ AND FOLLOW THE MANUFACTURER S INSTRUC TIONS EMPLOYER S SAFETY PRACTICES AND MATERIAL SAFETY DATA SHEETS MSDS FOR CONSUMABLES READ THIS WARNING PROTECT YOURSELF amp OTHERS FUMES AND GASES can be dangerous e Keep your head out of fumes 2 Use ventilation or exhaust at the arc or both to keep
52. ld slide easily Field Service Facility through the gun Verify the proper gun liner is installed Adjust the pressure arm On bench models make sure the brake tension is not too tight If using a wire conduit verify the wire slides easily through the conduit The wire continues to feed when the 1 Check if the 2 step Trigger trigger is released Interlock switch is in the TRIG GER INTERLOCK position Verify operation of the gun trig ger No shielding gas Verify the gas supply is turned on and not empty Check the gas hose for cuts Make sure it is not crushed Verify the shielding gas hose is connected to the gun bushing or welding gun CAUTION lf for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LF 72 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Variable or hunting arc Check for proper size contact Make sure the contact tip is not worn free of spatter and not melt ed Clean and tighten all electrode and work connections Verify the proper polarity is being used for the weld procedure Make sure the proper electrode stick out is being maintained Check the g
53. n can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment 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 equipment Save this manual and keep it handy for quick 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 TABLE OF CONTENTS Page icri m
54. n off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment 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 Jan 09 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 S ret 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 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 m
55. otec tion Connect the wire feeder only to power sources with overcurrent protection of no more than 15 amps POWER SOURCE WIRE FEEDER E FUNCTION LEAD Reserved Le trigger from feeder AN trigger from feeder Remote Voltage Control supply from feeder or remote control signal from feeder or remote Remote Voltage Control supply from feeder or remote Reserved o H 42 VAC Reserve for Future Use K 42VAC Reserve for Future Use Unused Electrode voltage from feeder 67 Do not use more than 100 ft 30 5 m of control cable between the wire feeder and power source LF 72 LINCOLN A 6 A 7 INSTALLATION A 7 ANALOG MILLER CONTROL CABLE ADAPTER K2335 1 This Lincoln Electric wire feeder may be mounted to a limit ed number of Miller Electric power sources The Miller power source must have the amphenol pin definition shown in the table below for proper operation of the wire feeder Operation of Lincoln wire feeders on Miller power sources may result in lack of high speeds or reduce pull force on high wire feed speeds Maximum wire feed speed for the LF 72 operating on a Miller power source is approximately 720ipm Be sure the Miller power source provides 24 VAC to the wire feeder and has overcurrent protection of no more than 15 amps The power source must not exceed 113VDC peak POWER SOURCE WIRE FEEDER JO 9A AO IO Ox OB
56. r at the welding power source 2 Remove the snap ring holding the ball bushing assembly to the back of the wire feeder Remove the ball bushing assembly FIGURE A 12b 2 BALL 3 BUSHING gt ASSEMBLY O RING S ds 4 K h 3 Remove the three socket head cap screws from the ball bushing assembly Caution as the screws are being loosened the balls may fall free from the assembly Remove the balls and the steel washer FIGURE A 13 c HOUSING gt me gt M NM Ead FL 25 Da 4 25 4 i V BALL SCREW BEARINGS 4 Place the ball bushing housing into the wire feeder case and secure with the snap ring or O ring depending on which code your machine uses LF 72 LINCOLN A 17 INSTALLATION BASE MODEL LF 72 LINCOLN A 18 INSTALLATION A 18 TYPICAL SYSTEM CONFIGURATIONS The LF 72 is capable of welding with many different welding processes These processes may require reconfigur ing the LF 72 with other products that may or may not be included with the model you purchased Use the Table 1 and 2 below to identify the basic items which are included in the LF 72 to utilize the various Welding Processes that the machine is capable of controlling TABLE 1 PART NO Wire Reel Stand Drive Roll Kit CONTROL Feeder CABLE K2327 1 Base Model d K2327 2 Bench Model Standard duty up to Standard Duty 15 Magnum 400 44 Ib 20 k
57. raparound The door is not shown for clarity See Figure D 1 4 Open the idle arm 5 Turn power on to the LF 72 LF 72 LINCOLN D 2 MAINTENANCE D 2 FIGURE D 1 5 h ut hi A H iS E E ode 1 E pea oe V 1 S MK E Y q e d 2 Si dr AL Ba p 6 Adjust the WFS knob to 300 ipm Center the knob pointer with the name plate graphics Activate the gun trigger 7 Insert the shorting plug into connector J2 on the p c board The shorting plug shorts pins 1 amp 5 See Figure D 2 8 Remove the shorting plug Set aside For Codes below 11289 use 9 thru 17 9 Adjust the WFS knob to minimum 10 Insert the shorting plug into connector J2 11 Adjust the WFS knob until the motor measures 51 5 5 ipm 9 5 1 0 rpm 12 Remove the shorting plug 13 Adjust the WFS knob to maximum 14 Insert the shorting plug into connector J2 15 Adjust the WFS until the motor measures 793 5 5 ipm 146 7 1 0 rpm 16 Remove the shorting plug 17 Release the gun trigger For Codes above 11290 use 18 18 Replace P2 from the harness into connector J2 19 Turn off power 20 Secure the wraparound to the LF 72 with 5 screws To calibrate the LF 72 for Codes 11606 thru 11609 1 Turn off power to the LF 72 and welding power source 2 Disconnect the electrode lead from the feed plate and from the welding power source 3 Remove the wraparound
58. rk and ground and could remain energized several seconds after the gun trigger is released Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform mainte nance work Calibration of the LF 72 may be required when the p c board potentiometer or motor is replaced or serviced Calibration matches the scale on the name plate to the actual wire feed speed To verify if calibration is necessary 1 Turn off power to the LF 72 2 Assemble 045 drive rolls inner guide and the outer guide into the drive Remove the gun from the wire feeder if assembled 3 Load 045 wire into the drive Cut the wire flush with the end of the gun bushing 4 Set the WFS knob to 300 ipm 5 Using the COLD FEED switch feed wire for 10 seconds 6 Cut the wire flush with the end of the gun bushing Measure the length of the wire If the wire mea sures 50 2 5 inches then calibration is not required Tools required applies to all codes that follow 5 16 nut driver 3 4 open end wrench WFS meter or RPM meter Shorting plug The shorting plug shorts pins 1 amp 5 of connector J2 on the p c board J2 is a 6 pin molex connector To calibrate the LF 72 for Codes 11075 thru 11293 1 Turn off power to the LF 72 2 Disconnect the electrode lead from the feed plate and from the welding power source 3 Remove the 5 screws securing the w
59. rol See Accessory Section For Kit Number Location for Optional Burnback and Postflow Timer Kit See Accessory Section For Kit Number 3 1 2 Thermal LED Motor Overload 4 5 2 Step Trigger Interlock switch Wire Feed Speed Knob y Gun Receiver Bushing Trigger Connector 5 amphenol for connecting the MIG gun trigger See Installation Section for detail LF 72 LINCOLN Cold Feed Gas Purge Switch press the switch up to feed wire with weld output off Press the switch down for gas flow with weld output off B 4 OPERATION B 4 1 REMOTE VOLTAGE CONTROL KIT The optional remote voltage control kit adjusts the arc voltage from the minimum to the maximum volt age of the welding power source Rotate the knob counterclockwise to reduce the arc voltage and rotate the knob clockwise to raise the arc voltage 2 BURNBACK AND POSTFLOW TIMER KIT The optional Burnback and Postflow Timer Kit gives control over the shielding gas at the end of the weld and prepares the end of the wire for the next arc start Additional shielding gas protection is often required when welding aluminum stainless steel or exotic alloys When stitch welding set the postflow time to maxi mum for best results Burnback Timer The burnback timer range is OFF to 0 25 seconds The burnback timer controls the additional amount of time the power source output remains ON after the wire drive has stopped feeding wire Burnback
60. sed Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes e Only qualified personnel should perform maintenance work Observe all additional Safety Guidelines detailed throughout this manual HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you Step 3 RECOMMENDED COURSE OF ACTION locate and repair possible machine malfunctions This column provides a course of action for the Simply follow the three step procedure listed below Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP If you do not understand or are unable to perform the TOMS This column describes possible symptoms Recommended Course of Action safely contact your that the machine may exhibit Find the listing that local Lincoln Authorized Field Service Facility best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled PO
61. shows the orientation of the brake holding pin Be certain the wire feeds off of the spool in the proper direction INSTALLATION A 12 3 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle FIGURE A 8 Retaining Collar Loading 30 Ib 13 6 kg Readi Reels See Figure A 9 A K363 P Readi Reel adapter is required for loading these spools on 2 51mm spindles 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the Readi Reel adapter on the spindle align ing the spindle brake pin with one of the holes in the adapter 3 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle 4 Rotate the spindle and adapter until the retaining spring is at the 12 o clock position 5 Position the Readi Reel so that electrode de reels in the proper direction 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring 7 Lower the Read Reel to depress the retaining spring and align the other inside cage wires with the grooves in the adapter 8 Slide the cage all way onto the adapter until the retaining spring pops up fully Removing a Readi Reel 1 To remove a Readi Reel from the an adapter depress the retaining spring with a thumb while pulling the Readi Reel cage from the adapter
62. t it to the flow rate recommended for the procedure and process being used before making a weld LF 72 LINCOLN A 15 INSTALLING ELECTRODE CONDUIT KITS WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the dis connect switch before working on this equipment Do not touch electrically hot parts Electrode conduit is used when feeding wire drums from boxes or large reels For best feeding results use the shortest conduit length possible and avoid sharp bends For Codes 11075 11076 11077 Tools required See Figure A 10a Snap Ring Pliers To install Lincoln conduit 1 Turn off power at the welding power source 2 Remove the snap ring holding the ball bushing assembly to the back of the wire feeder Remove the ball bushing assembly FIGURE A 10a Hu BALL 3 BUSHING 8 ASSEMBLY INSTALLATION A 15 For Codes 11209 11210 11211 and above To install Lincoln conduit See Figure A 10b 1 Turn off power at the welding power source 2 Remove the O ring holding the ball bushing assembly to the back of the wire feeder Remove the ball bushing assembly FIGURE A 10b EPI BALL 3 BUSHING 7 ASSEMBLY d p A O 7 3 Place a K1546 xx conduit connector into the back of the wire drive Rotate the conduit connector to a position where the thumb screw does not interfere with the idle arm or door 4 Tighten the set scr
63. t parts LOCATION The LF 72 may be placed on a bench or mounted on top of a welding power source Place the LF 72 in aclean and dry location Do not stack the LF 72 MOUNTING For location and size LF 72 Bench Model Rear Mounting Holes See Figure A 1 and for Bottom Mounting Holes See Figure A 2 FIGURE A 1 7 83 2 76 5116 18 Places 8 09 FIGURE A 2 LF 72 LINCOLN A 3 INSTALLATION A 3 BENCH MOUNT BOOM MOUNT The LF 72 mounts in a variety of configurations As When boom mounting remove the wire reel stand if shipped from the factory the LF 72 is suitable for assembled and secure the wire feeder directly to the bench mounting or placing directly on top of the weld desired surface ing power source CV xxx and DC xxx product family only AN zai Bench Mount SUSPENDED SWIVEL MOUNT Only suspend the wire feeder by the lift bail of the Both the standard duty bench model and heavy duty POrtability kit bench model may be mounted onto a swivel when a top a welding power source Swivel Kit and Bench Model Standard Duty WARNING Alternative methods for hanging the wire feeder must not be used unless insulation is provided Swivel Kit and Base Model LF 72 between the wire feeder enclosure and the hang 2227 ing device i i LF 72 LINCOLN A 4 INSTAL
64. ts and mounting hardware Insulated Lift Bail Includes Insulated Lift Bail for use with Heavy Duty Bench and mounting hardware Models LF 72 LINCOLN C 4 D 1 MAINTENANCE D 1 CALIBRATION SPECIFICATION WARNING MAINTENANCE Safety Precautions A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or inter nal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes e Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform mainte nance work Observe all additional Safety Guidelines detailed throughout this manual ROUTINE MAINTENANCE Clean and tighten all weld terminals Inspect all weld cables control cables gun cables and shielding gas hoses Repair or replace as nec essary PERIODIC MAINTENANCE Clean drive roll grooves Blow out or vacuum the inside of the feeder ELECTRIC SHOCK can kill not touch electrically live parts When inching with the gun trigger electrode wire drive motor and drive mechanism are hot to wo
65. utomatic DC Constant Voltage Wire Welder DC Manual Stick 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 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 standards 4 6 Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc
66. wire feeder for STT welding WIRE DRIVE SYSTEMS Drive Roll Kits are designed to feed specific types and wire sizes The LF 72 Bench Model comes with the combo KP1696 1 All other Drive Roll Kits listed are not included available for ordering from the Drive Roll Kits Steel Wires Includes 2 Smooth V groove drive rolls and an inner wire guide KP1696 030S KP1696 035S 035 0 9mm KP1696 045S 045 1 2mm 023 030 0 6 0 8mm KP1696 052S 052 1 4mm KP1696 1 16S 1 16 1 6mm KP1696 1 035 045 0 9 1 2mm KP1696 2 040 1 0mm Drive Roll Kits Cored Wires Includes 2 Knurled drive rolls and an inner wire guide KP1697 035C KP1697 045C KP1697 052C KP1697 1 16C KP1697 068 KP1697 5 64C 030 035 0 8 0 040 045 1 0 1 052 1 1 16 1 6mm 068 072 1 7 1 8mm 5 64 2 0mm Drive Roll Kits Aluminum Wire Includes 2 polished U groove drive rolls outer wire guide and an inner wire guide KP1695 035A KP1695 040A KP1695 3 64A KP1695 1 16A 035 0 9 mm 040 1 0mm 3 64 1 2mm 1 16 1 6mm INNER WIRE GUIDE LF 72 LINCOLN A 9 WELDING GUNS TORCHES AND ACCES SORIES GUN RECEIVER BUSHING The LF 72 wire feeder comes with a K1500 2 gun receiver bushing MAGNUM GUN AND CABLE ASSEMBLIES The LF 72 wire feeder model will accept a number of optional gun and cable assemblies An example of installing the Gun and Cable is shown in Figure A 3 with a 15 ft 4 6m
67. with both hands Do not remove the adapter from the spindle LF 72 LINCOLN A 13 INSTALLATION FIGURE A 9 ADAPTER SPINDLE HL RETAINING SPRING GROOVES WELD WIRE ROUTING The electrode supply may be either from reels Readi Heels spools or bulk packaged drums or reels Observe the following precautions a The electrode must be routed to the wire drive unit so that the bends in the wire are at a mini mum and also that the force required to pull the wire from the reel into the wire drive unit is kept at a minimum The electrode is hot when the gun trigger is pressed and must be insulated from the boom and structure If more than one wire feed unit shares the same boom and are not sharing the some power source output stud their wire and reels must be insulated from each other as well as insulated from their mounting structure m LF 72 LINCOLN RELEASE BAR RETAINING COLLAR A 13 A 14 SHIELDING GAS CONNECTION where it may be damaged e Never lift welder with cylinder attached e Never allow welding electrode to touch cylinder e Keep cylinder away from welding or other live electrical circuits BUILD UP OF SHIELDING GAS may harm health or kill Shut off shielding gas supply when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY Maximum inlet pressure is 100 psi 6 9

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