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Lincoln Electric LF-72 Operator's Manual

For use with machines having code numbers: 12454
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Operator's Manual
LF-72 WIRE FEEDER
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10258
| Issue D ate Apr-15
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12454

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Summary of Contents for Lincoln Electric LF-72

  • Page 1 Operator’s Manual LF-72 WIRE FEEDER For use with machines having Code Numbers: 12454 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10258 | Issue D ate Apr-15...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Installation......................Section A Technical Specifications ....................A-1 Safety Precautions .......................A-2 Location........................A-2 Mounting ........................A-2 Bench Mount......................A-3 Swivel Mount ......................A-3 Boom Mount ......................A-3 Suspended.......................A-3 Weld Cable Sizes .....................A-4 Coaxial Weld Cables....................A-5 Weld Cable Connections ..................A-5 Analog Control Cable Connections ................A-6 Analog Miller Control Cable Adapter................A-7 Welding Gun/Wire Feeder Trigger Connector............A-8 High Frequency Protection ..................A-8...

  • Page 7: Table Of Contents

    Safety Precautions ....................E-1 How To Use Troubleshooting Guide ..............E-1 Troubleshooting Guides.................E-2, E-3 ________________________________________________________________________ Wiring Diagram and Dimension Prints ............Section F ________________________________________________________________________ Parts List .........................parts.lincolnelectric.com Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com. ______________________________________________________________________ LF-72...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS: LF-72 WIRE FEEDER SPEC.# TYPE WIRE FEED SPEED RANGE Wire Size LF-72 Speed Solid Cored K2327-9 Bench Model 50-800 IPM .023 - 1/16 in. .035 - 5/64 in Standard Duty (1.27-20.3 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm) CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS SPEC.#...

  • Page 9: Location

    • Do not touch electrically hot 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 a clean and dry location. Do not stack the LF-72.

  • Page 10: Bench Mount

    BENCH MOUNT BOOM MOUNT When boom mounting, remove the wire reel stand (if The LF-72 mounts in a variety of configurations. As assembled) and secure the wire feeder directly to the shipped from the factory, the LF-72 is suitable for desired surface.

  • Page 11: Weld Cable Sizes

    0 to 15 m 15 to 31 m 4 or 5 40 & 30 ** 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...

  • Page 12: Coaxial Weld Cables

    Coaxial weld cables are recommended for all pulse and STT welding, especially when the total weld tight metal to metal electrical contact. Poor work lead connections can result in poor welding cable length (electrode cable + work cable) exceeds performance. 50 feet (7.6m) LF-72...
  • Page 13 (“-” supply from feeder or remote) Reserved 42 VAC Reserve for Future Use. 42 VAC Reserve for Future Use. Unused ------- Electrode voltage from feeder Do not use more than 100 ft (30.5 m) of control cable between the wire feeder and power source. LF-72...

  • Page 14: Analog Miller Control Cable Adapter

    Arc Voltage feedback to feeder. Reserved for future use. Scaled 0-10V. 1 V = 10 Arc volts. Referenced to pin D. Electrode voltage to power source (67) Miller is a registered trademark not owned or licensed by The Lincoln Electric Company. LF-72...

  • Page 15: Welding Gun/Wire Feeder Trigger Connector

    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, but are available for ordering from...

  • Page 16: Welding Guns, Torches And Accessories

    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. 1. Turn off power at the welding power source.

  • Page 17: Procedure For Changing Drive And Idle Roll Sets

    7. 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. LF-72...

  • Page 18: Pressure Arm Adjustment

    Steel, Stainless wires between 4 and 6 FIGURE A.6 K1500-3 K1637-7 Lincoln gun connectors; Magnum 550 guns and compatible with Tweco® #5) K1500-4 K466-3 Lincoln gun connectors; compatible with Miller® guns.) K1500-5 (Compatible with Oxo® guns.) K489-7 ( Lincoln Fast-Mate guns.) LF-72...

  • Page 19: Wire Reel Loading

    An indicator mark on the end of the spindle shows the orientation of the brake holding pin. Be certain the wire feeds off of the spool in the proper direction. LF-72...

  • Page 20: Weld Wire Routing

    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. LF-72...

  • Page 21: Shielding Gas Connections

    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 cylinder. LF-72...

  • Page 22: Installing Electrode Conduit Kits

    4. Tighten the set screw to secure the conduit con- nector 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.

  • Page 23: Aluminum Wire Preparations

    Remove the balls and the steel washer. FIGURE A.13 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...

  • Page 24: Typical System Configurations

    LF-72 with other products that may or may not be included with the model you purchased. Use the table 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.

  • Page 25: Operation

    OPERATION SAFETY PRECAUTIONS The serviceability of a product or structure utilizing the LF-72 wire feeder is and must be the sole Read this entire section of operating instructions responsibility of the builder/user. Many variables before operating the machine. beyond the control of The Lincoln Electric Company...

  • Page 26: Common Welding Abbreviations

    Magnum (Tweco #2-#4 compatible) back needs of customers using 60 lb (27.2 kg) spools. end. • The LF-72 does not attach to K303 wire reel stands. General Functional Description • The LF-72 is a highly versatile and economical choice of industrial feeders.

  • Page 27: Front Panel Controls And Connections

    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. 2 step - Trigger Interlock switch. Wire Feed Speed Knob. Gun Receiver Bushing. Trigger Connector 5-pin amphenol for connecting the MIG gun trigger. See Installation Section for detail. LF-72...

  • Page 28: Remote Voltage Control Kit (Optional

    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 2. BURNBACK AND POSTFLOW TIMER KIT Cold Feed and Gas Purge are combined into a single spring centered toggle switch.

  • Page 29: Wire Feed Speed Knob

    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®...

  • Page 30: Accessories

    Mate, 2/0 Cable for 50' (15.2m) cables. Includes: Lug to Lug, 3/0 Cable of length "xx" for K1842-xx Weld Power Cable, Lug to Lug. lengths up to 60' (18.3m). Lug to Lug, 4/0 Cable of length "xx" for lengths greater than 60' (18.3m). LF-72...
  • Page 31 K466-2, K466-10 Lincoln gun con- ing with hose nipple, set (standard on all nectors; Magnum 200/300/400 guns screw 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 tors;...
  • Page 32 Heavy Duty Bench models. Coil Adapter, for mounting K1504-1 50-60 lb. (22.7 - 27.2 kg) coils to Includes: 50-60 lb. (22.7 - 2 in (51 mm) spindles. 27.2 kg) coil adapter. For use with heavy Duty Bench models. LF-72...
  • Page 33 Light Duty Caster Kit (for use with Includes: 2 Swivel Casters, 2 Heavy Duty Bench Models) Fixed Casters, brackets and mounting hardware. Insulated Lift Bail Includes: Insulated Lift Bail K1555-1 (for use with Heavy Duty Bench and mounting hardware. Models) LF-72...

  • Page 34: Periodic Maintenance

    • Turn OFF input power at welding power source ----------------------------------------------------------- before installation or changing drive roll and/or Calibration of the LF-72 may be required when the guide tubes. p.c. board, potentiometer or motor is replaced or ser- viced. Calibration matches the scale on the name •...
  • Page 35 MAINTENANCE FIGURE D.1 1. Replace P2 from the harness into connector J2. 2. Turn off power. 3. Secure the wraparound to the LF-72 with 5 screws. LF-72...

  • Page 36: How To Use Troubleshooting Guide

    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.
  • Page 37 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...
  • Page 38 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION Variable or "hunting" arc. 1. Check for proper size contact. Make sure the contact tip is not worn, free of spatter and not melted.
  • Page 39 DIAGRAMS LF-72...
  • Page 40 DIMENSION PRINTS BENCH MODEL HEAVY DUTY BENCH MODEL BENCH MODEL STANDARD DUTY LF-72...
  • Page 41 ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● No toque las partes o los electrodos ●...
  • Page 42 ● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or WARNING ● Use ventilation or exhaust to remove guards off. fumes from breathing zone. Spanish ● Los humos fuera de la zona de res- ●...
  • Page 43 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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