Page 2 - SAFETY; PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; WARNING; ELECTRIC AND; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ; PRÉCAUTIONS DE SÛRETÉ POUR
iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contr...
Page 6 - TABLE OF CONTENTS; TThhaannkk Y; Please Examine Carton and Equipment For Damage Immediately
v v TABLE OF CONTENTS TThhaannkk Y Yoouu for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this...
Page 8 - vii
vii TABLE OF CONTENTS LF-72 vii Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance......
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS: LF-72 Wire Feeder; WELDING CAPACITY RATING
A-1 INSTALLATION LF-72 A-1 TECHNICAL SPECIFICATIONS: LF-72 Wire Feeder SPEC.# TYPE WIRE FEED SPEED RANGE Dimensions do not include wire reel. Wire Size LF-72 Speed Solid Cored K2327-1 K2327-4 K2327-2 Bench Model 50-800 IPM .023 - 1/16 in. .035 - 5/64 in K2327-5 Standard Duty (1.27-20.3 m/m) (0.6 - 1...
Page 10 - SAFETY PRECAUTION; LOCATION; ELECTRIC SHOCK can kill.
A-2 INSTALLATION LF-72 A-2 SAFETY PRECAUTION LOCATION The LF-72 may be placed on a bench or mounted on top of a welding power source. Place the LF-72 in a clean and dry location. Do not stack the LF-72. ELECTRIC SHOCK can kill. • O n l y q u a l i f i e d p e r s o n n e l s h o u l d perform this i...
Page 11 - BENCH MOUNT; Alternative methods for hanging the wire feeder; Bench Mount
A-3 INSTALLATION LF-72 A-3 BENCH MOUNT The LF-72 mounts in a variety of configurations. As shipped from the factory, the LF-72 is suitable for bench mounting or placing directly on top of the weld- ing power source (CV-xxx and DC-xxx product family only). SWIVEL MOUNT Both the standard duty bench mo...
Page 12 - WELD CABLE SIZES
A-4 INSTALLATION LF-72 A-4 SAFETY PRECAUTION E L E C T R I C S H O C K c a n kill. • O n l y q u a l i f i e d p e r s o n n e l s h o u l d perform this installation. • 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 ...
Page 13 - COAXIAL WELD CABLES; Electrode
A-5 INSTALLATION LF-72 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 fast changes in the weld current. Regular cables have a higher inductance which may distort the pulse or ...
Page 14 - ANALOG CONTROL CABLE; CONTROL CABLE CONNECTIONS; PIN; POWER SOURCE
A-6 INSTALLATION LF-72 A-6 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 overcurr...
Page 15 - A N A L O G M I L L E R C O N T R O L C A B L E; MILLER POWER SOURCE; LINCOLN WIRE FEEDER; Pin
A-7 INSTALLATION LF-72 A-7 A N A L O G M I L L E R C O N T R O L C A B L E 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 operat...
Page 16 - Wire Feeder; HIGH FREQUENCY PROTECTION; Trigger Lead; REMOTE SENSE LEAD SPECIFICATIONS; WIRE DRIVE SYSTEMS; Drive Roll Kits, Steel Wires
WELDING GUN/WIRE FEEDER TRIGGER CONNECTOR Wire Feeder Pin Function A Gun Trigger B - C Common D - E - 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...
Page 17 - SORIES; GUN RECEIVER BUSHING
LF-72 LF-72 A-9 INSTALLATION LF-72 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 in...
Page 18 - WIRE DRIVE CONFIGURATION
WIRE DRIVE CONFIGURATION (See Figure A.5) Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch or fuse box before a t t e m p t i n g t o c o n n e c t o r d i s c o n - n e c t i n p u t p o w e r l i n e s , o u t p u t cables or control ...
Page 19 - PRESSURE ARM ADJUSTMENT
A-11 INSTALLATION LF-72 A-11 PRESSURE ARM ADJUSTMENT ELECTRIC SHOCK can kill. • T u r n t h e i n p u t p o w e r O F F a t t h e 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 a...
Page 20 - WIRE REEL LOADING
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. Loading 30 lb. (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. Squ...
Page 21 - WELD WIRE ROUTING
A-13 INSTALLATION LF-72 A-13 WELD WIRE ROUTING The electrode supply may be either from reels, Readi- R e e l s , s p o o l s , o r b u l k p a c k a g e d d r u m s o r r e e l s . Observe the following precautions: a) The electrode must be routed to the wire drive unit so that the bends in the wire...
Page 22 - SHIELDING GAS CONNECTION
A-14 INSTALLATION LF-72 A-14 SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • K e e p c y l i n d e r a w a y f r o m a r e a s where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cyl...
Page 23 - INSTALLING ELECTRODE; ELECTRIC SHOCK can kill.
A-15 INSTALLATION LF-72 A-15 INSTALLING ELECTRODE CONDUIT KITS 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 co...
Page 24 - ALUMINUM WIRE PREPARATIONS
A-16 INSTALLATION LF-72 A-16 ALUMINUM WIRE PREPARATIONS 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 alumin...
Page 25 - BENCH MODEL STANDARD DUTY
A-17 INSTALLATION LF-72 A-17 BENCH MODEL STANDARD DUTY BENCH MODEL HEAVY DUTY BASE MODEL
Page 26 - TYPICAL SYSTEM CONFIGURATIONS; TABLE 1
A-18 INSTALLATION LF-72 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 ide...
Page 27 - OPERATION; SAFETY PRECAUTIONS
B-1 OPERATION B-1 LF-72 COLD FEED POSITIVE OUTPUT NEGATIVE OUTPUT PROTECTIVE GROUND WARNING OR CAUTION DANGEROUS VOLTAGE SHOCK HAZARD WELDING FUMES EXPLOSION GAS INPUT WORK CONNECTION SAFETY PRECAUTIONS Read this entire section of operating instructionsbefore operating the machine. ELECTRIC SHOCK ca...
Page 28 - COMMON WELDING ABBREVIATIONS
B-2 OPERATION B-2 LF-72 COMMON WELDING ABBREVIATIONS WFS • Wire Feed Speed CV • Constant Voltage GMAW (MIG) • Gas Metal Arc Welding FCAW (Cable Innershield or Outershield) • Flux Core Arc Welding PRODUCT DESCRIPTION General Physical Description The LF-72 is optimized for .035 through .045 (0.9mm thr...
Page 29 - ITEM; FRONT PANEL CONTROLS AND CONNECTIONS
B-3 OPERATION B-3 ITEM DESCRIPTION 1 Location for Optional Remote Voltage Control (See Accessory Section For Kit Number) . 2 Location for Optional Burnback and Postflow Timer Kit (See Accessory Section For Kit Number). 3 Thermal LED, Motor Overload. 4 Cold Feed - Gas Purge Switch, press the switch u...
Page 30 - REMOTE VOLTAGE CONTROL KIT; BURNBACK AND POSTFLOW TIMER KIT; optional
B-4 OPERATION B-4 LF-72 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 volta...
Page 31 - WIRE FEED SPEED KNOB; CAUTION
B-5 OPERATION B-5 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 feeder feeds wire for welding. The gun trigger is then released while the weld is m...
Page 32 - ACCESSORIES
C-1 ACCESSORIES C-1 LF-72 OPTIONAL KITS: K2329-1 K2330-1 K2328-1 K2331-1 K2332-1 K1796-xx K1803-1 K1840-xx K1841-xx K1842-xx Remote Voltage Control Kit. Timer Kit. Standard Duty Wire Reel Stand. Lift Bail Kit. Swivel Kit. (for use with Standard Duty Bench Models) Co-Axial Power Cable. Work and Feede...
Page 36 - MAINTENANCE; Safety Precautions; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 LF-72 MAINTENANCE Safety Precautions 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 secon...
Page 38 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE; • Do not touch electrically live parts.
E-1 TROUBLESHOOTING E-1 LF-72 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. CAUTION This Troubleshooting Guide is...
Page 39 - PROBLEMS; Contact
E-2 TROUBLESHOOTING E-2 LF-72 Observe all Safety Guidelines detailed throughout this manual 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 assist...
Page 41 - WIRING DIAGRAM; LF
F-1 WIRING DIAGRAM F-1 LF-72 LF -7 2 FE ED ER (1 10 75 , 1 10 76 , 1 10 77 ) L 1 2 1 4 6 A CA VI TY N UM BE RI NG S EQ UE NC E (C O M PO NE NT S ID E O F P. C. B O AR D) J3 2 1 J5 ,J 8 J9 ,J 60 4 3 6 1 GE NE RA L I NF OR MA TI ON EL EC TR IC AL S YM BO LS P ER E 15 37 CO LO R CO DE B - BL AC K R - R...
Page 43 - DIAGRAMS; Enhanced Diagram
F-3 DIAGRAMS F-3 LF-72 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a...
Page 45 - DIMENSION PRINTS; BENCH MODEL
F-5 DIMENSION PRINTS F-5 LF-72 BENCH MODEL BENCH MODEL STANDARD DUTY
Page 46 - BENCH MODEL HEAVY DUTY
F-6 DIMENSION PRINTS F-6 LF-72 BENCH MODEL HEAVY DUTY