Lincoln Electric FLEX FEED 74 HT Operator's Manual
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Lincoln Electric FLEX FEED 74 HT Operator's Manual

Lincoln Electric FLEX FEED 74 HT Operator's Manual

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Operator's Manual
FLEX FEED
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10163
| Issue D ate Nov-13
© Lincoln Global, Inc. All Rights Reserved.
74 HT
™
For use with machines having Code Numbers:
12039 - 12052

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Summary of Contents for Lincoln Electric FLEX FEED 74 HT

  • Page 1 Operator’s Manual FLEX FEED 74 HT ™ For use with machines having Code Numbers: 12039 - 12052 Register your machine: www.lincolnelectric.com/registration Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10163 | Issue D ate Nov-13 ©...
  • Page 2 THANK YOU FOR SELECTING KEEP YOUR HEAD OUT OF THE FUMES. A QUALITY PRODUCT BY DON’T get too close to the arc. Use LINCOLN ELEC TRIC. corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety PLEASE EXAMINE CARTON AND EQUIPMENT FOR Data Sheet (MSDS) and the warning DAMAGE IMMEDIATELY...

  • Page 3: Section A: Warnings

    American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, 2.a.

  • Page 4: Electric Shock Can Kill

    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 FLEX FEED™ 74 HT TABLE OF CONTENTS...

  • Page 7: Product Description

    PRODUCT DESCRIPTION GENERAL PHYSICAL DESCRIPTION The Flex Feed 74 HT is a heavy duty industrial wire feeder. At the heart of the feeder is the proven wire drive and motor, capa- ble of feeding large diameter electrodes and pulling through long conduits.

  • Page 8: Input Voltage And Current

    FLEX FEED™ 74 HT INSTALLATION TECHNICAL SPECIFICATIONS – FLEX FEED™ 74 HT (K3883-XX) INPUT VOLTAGE and CURRENT VOLTAGE NOTES INPUT AMPERES 24 – 42 VAC Wire Drive RATED OUTPUT @ 104°F (40°C) INPUT AMPERES DUTY CYCLE No Gouging Kit 600 Amps Wire Drive Wire Drive 500 Amps...
  • Page 9 FLEX FEED™ 74 HT INSTALLATION MODEL NUMBERS FOR BASIC AND ADVANCED USER INTERFACE MODEL K# User Interface Wire Reel Stand Gouging Kit K3883-1 Basic K3883-2 Advanced K3883-3 Basic K3883-4 Advanced K3883-5 Basic Standard Duty K3883-6 Advanced Standard Duty K3883-7 Basic Standard Duty K3883-8 Advanced...

  • Page 10: Safety Precautions

    FLEX FEED™ 74 HT INSTALLATION SAFETY PRECAUTIONS LOCATION The Flex Feed 74 HT is rated IP2X and is suitable WARNING for indoor use. ELECTRIC SHOCK CAN KILL. For best wire feeding performance, place the Flex • ONLY QUALIFIED PERSONNEL Feed 74 HT on a stable and dry surface.
  • Page 11 FLEX FEED™ 74 HT INSTALLATION FEED PLATE PRESSURE ADJUSTMENT (See Figure A.2) • Most wires operate well with a pressure setting of “2”. The best drive roll pressure varies with wire type, wire surface, lubrication and hardness. Too much pressure may crush the wire or cause "birdnesting", but too lit- tle pressure could cause slippage.
  • Page 12 FLEX FEED™ 74 HT INSTALLATION GUN ADAPTERS: K3344-1 LINCOLN K3345-1 STANDARD #4 K3346-1 STANDARD #5 K3347-1 MILLER GUN ADAPTER REPLACEMENT PROCEDURE 1. Turn power OFF at the welding power source. 2. Using a Phillips screw driver, loosen the screw securing the gun adapter cover. Remove the gun adapter cover.
  • Page 13 FLEX FEED™ 74 HT INSTALLATION 4. Use a 1/8” hex key to loosen the set screw securing the gun adapter. FIGURE A.5 SET SCREW GUN ADAPTER...

  • Page 14: Set Screw

    FLEX FEED™ 74 HT INSTALLATION 5. Remove the sense lead with a Phillips screw driver. FIGURE A.6 SENSE LEAD 6. If a gas hose is attached to the gun adapter, use pliers to remove the hose clamp and remove the gas hose. 7.
  • Page 15 FLEX FEED™ 74 HT INSTALLATION 8. Assemble the sense lead to the new gun adapter. Orient the lead to towards the rear of the gun adapter. 9. If required, assemble the gas hose to the gun adapter or the fitting on the feed plate and secure with a hose clamp.
  • Page 16 FLEX FEED™ 74 HT INSTALLATION GUN ADAPTERS: K3348-1 OXO K3349-1 FASTMATE • Using the Oxo or FastMate gun adapters requires a K3344-1 Standard #4 gun adapter to be installed in the wire drive. 1. Turn power OFF at the welding power source. 2.
  • Page 17 FLEX FEED™ 74 HT INSTALLATION 4. Using pliers, remove the hose clamp and hose from the gun adapter. 5. Bolt the electrode lead to the gun adapter, making sure to route the lead straight down. FIGURE A.12 BOLT ELECTRODE LEAD KEEP TERMINAL AND LEAD VERTICAL.
  • Page 18 FLEX FEED™ 74 HT INSTALLATION 6. Assemble the gun adapter cover and secure with the screw. FIGURE A.13 SCREW ADAPTER COVER 7. Assemble the gas hose to the Oxo or FastMate gun adapter. 8. Select the appropriate guide tube and secure with the set screw.
  • Page 19 FLEX FEED™ 74 HT INSTALLATION PINION GEAR RATIO As shipped from the factory, a 20 tooth pinion gear is installed. If desired, the 30 tooth pinion gear may be installed for more speed but less torque. FIGURE A.15 1. Turn power OFF at the welding power source. 2.
  • Page 20 FLEX FEED™ 74 HT INSTALLATION 3. Remove the two socket head cap screws securing the ROTATING THE FEED PLATE feed plate and remove the feed plate from clamp using a 1/4” hex key. 1. Turn power OFF at the welding power source. FIGURE A.17 2.
  • Page 21 4. Use a 1/8” hex key to loosen the set screw securing LEFT HAND WIRE DRIVE the gun adapter. FIGURE A.21 The Flex Feed 74 HT may be reassembled with the wire drive on the left hand side. To convert to a left hand wire drive: SET SCREW...
  • Page 22 FLEX FEED™ 74 HT INSTALLATION 8. Remove the (4) screws securing the roof with a 5/16” 10. Remove the upper motor support. Use a 5/16” nut nut driver. Remove the remaining (2) screws securing driver to remove the (2) screws at the rear and the (2) each case side.
  • Page 23 FLEX FEED™ 74 HT INSTALLATION 12a. For feeders with digital displays only: a. Unbolt the wire drive lead from the bus bar with a 3/4” wrench. b. Unbolt the bus bar from the case (1/4” Hex key) and the input stud. c.
  • Page 24 FLEX FEED™ 74 HT INSTALLATION 14. Place the motor gearbox assembly in the case with Reassemble the switch on the left side the drive facing the left side. Secure with (4) screws. FIGURE A.30 15. Reassemble the upper motor support with plastic washers on the appropriate side.
  • Page 25 FLEX FEED™ 74 HT INSTALLATION 17. If present, reassemble the Gouge/Wire Feed switch on the opposite side. FIGURE A.32 552F 515E 515F 515G 18. Remove the (4) screws holding the user interface to gain access to the inside front compartment of the feeder.
  • Page 26 FLEX FEED™ 74 HT INSTALLATION 20. Swap the location of the plug button and the 5 pin trigger connection on the front of the feeder, then reassemble the user interface. FIGURE A.34 PLUG BUTTON 5 PIN TRIGGER CONNECTOR 21. Reassemble the gas solenoid and plug button to the rear of the feeder.
  • Page 27 FLEX FEED™ 74 HT INSTALLATION 24a. Open the feed plate door. a. Remove the screw holding the door insert. b. Remove the (2) socket head cap screws. c. Fully unscrew the pressure knob and slide the washers and rod out of the door. FIGURE A.37 DOOR INSERT AND SCREW...
  • Page 28 FLEX FEED™ 74 HT INSTALLATION 24b. To reassemble the door for left hand operation: a. Place the pressure arms on the door in the orientation as shown. b. Slide the rod through the door and through the springs. c. Assemble the socket head cap screws and indicator, tightening the indicator screw to a height of .27”...
  • Page 29 FLEX FEED™ 74 HT INSTALLATION 25. Place the gun adapter into the feed plate. If required, swap the position of the barbed fitting with the plug. Assemble the gas hose to the gun adapter. 26. Assemble the wire drive lead to the gun adapter. The bolt for the wire drive lead will align the gun adapter with the feed plate as the bolt is tightened.
  • Page 30 FLEX FEED™ 74 HT INSTALLATION WATER COOLING KIT The K590-6 water connection kit installs underneath the wire drive. 1. Turn power OFF at the welding power source. 2. Install the quick disconnect fittings to the plastic bracket, by holding the rear nut stationary and spinning the fitting.

  • Page 31: Shielding Gas Connection

    Welding and Cutting” Published by the American Welding Society. --------------------------------------------------------------- Maximum inlet pressure for the Flex Feed 74 HT is 100 psi. (6.9 bar.) The inlet fitting is 5/8-18 CGA type connection. Install the shielding gas supply as follows: 1.

  • Page 32: Loading Spools Of Wire

    FLEX FEED™ 74 HT INSTALLATION LOADING SPOOLS OF WIRE WARNING • Keep hands, hair, clothing and tools away from rotating equipment. • Do not wear gloves when threading wire or changing wire spool. • Only qualified personnel should install, use or service this equipment. -------------------------------------------------------------------------- 50 - 60 lb (22 –...
  • Page 33 FLEX FEED™ 74 HT INSTALLATION 3. 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 spindle shows the orientation of the brake holding pin. Be certain the wire feeds off of the spool in the proper direction.
  • Page 34 FLEX FEED™ 74 HT INSTALLATION WIRE REEL STANDS K3342-1 Standard Duty Wire Reel Stand is for use with spools 10 to 44 lb (4.5 to 20 kg) When using the K3343-1 Heavy Duty Wire Reel, place the spindle in the location as shown. FIGURE A.44 A-27...

  • Page 35: Electrical Installation

    FLEX FEED™ 74 HT INSTALLATION ELECTRICAL INSTALLATION 14 pin connector The control cable connecting the wire feeder to the power source is specially made for the welding environment. The wire feeder power requires overcurrent protection. Connect the wire feeder only to power sources where the overcurrent protection is no more than 15 amps.
  • Page 36 INSTALLATION NON-LINCOLN EQUIPMENT ADAPTER, K2335-1,-2 The Flex Feed 74 HT may be used with non-Lincoln Electric power sources that provide 24 VAC. The power source must have the circular connector pin definition shown in the table below for proper opera- tion of the wire feeder.

  • Page 37: Relay Connections

    FLEX FEED™ 74 HT INSTALLATION RELAY CONNECTIONS The Flex Feed 74 HT includes a DPDT relay for ™ switching power for accessories. The relay closes whenever the gas solenoid turns on. The ratings of the relay are: Normally Open 30 amps @ 277 VAC 20 amp @ 28 VDC Normally Closed 2 amps @ 480 VAC...
  • Page 38 FLEX FEED™ 74 HT OPERATION GRAPHIC SYMBOLS THAT APPEAR ON FLEX FEED 74 HT OR IN THIS MANUAL ™ WARNING OR CONTACTOR CAUTION COLD FEED INPUT POWER GAS PURGE SHIELDING GAS INLET SHIELDING GAS OUTLET POSITIVE OUTPUT PREFLOW NEGATIVE OUTPUT BURNBACK PROTECTIVE GROUND...
  • Page 39 FLEX FEED™ 74 HT OPERATION DUTY CYCLE The FLEX FEED™ 74 HT wire feeders are intended for semi-automatic use. The maximum rating of the FLEX FEED™ 74 HT is based upon a 60% duty cycle; welding 6 minutes of welding followed by 4 minutes of idling within a 10 minute period.

  • Page 40: Front View

    FLEX FEED™ 74 HT OPERATION FRONT VIEW (See Figure B.1) (ADVANCED USER INTERFACE SHOWN) FIGURE B.1 AMPS VOLTS DISPLAY DISPLAY REMOTE VOLTAGE CONTROL KNOB WIRE FEED SPEED KNOB PREFLOW BURNBACK POSTFLOW TRIGGER CONNECTOR (5 PIN) 2-STEP/TRIGGER INTERLOCK SWITCH SIDE VIEW (See Figure B.2) FIGURE B.2 COLD FEED/...

  • Page 41: Operation

    FLEX FEED™ 74 HT OPERATION REAR VIEW (See Figure B.3) ELECTRODE CONNECTION (COVER NOT SHOWN FOR CLARITY) SHIELDING GAS INLET CONTROL CABLE WITH 14 PIN CINNECTOR...

  • Page 42: Thermal Led

    REMOTE VOLTAGE CONTROL KNOB COLD FEED The remote voltage control knob adjusts the output of the power source. The Flex Feed 74 HT does not display Pressing the Cold Feed rocker switch feeds preset voltage. wire at the wire feed speed indicated by the knob without turning on the power source output.

  • Page 43: Power Up Sequence

    FLEX FEED™ 74 HT OPERATION POWER UP SEQUENCE 1. The thermal LED (location See Figure B.3) illuminates for 2 seconds. 2. If the trigger is already activated, the thermal LED will quickly blink until the trigger is released. FIGURE B.4 LED LOCATION LED LOCATION USER INTERFACE:...
  • Page 44 FLEX FEED™ 74 HT OPERATION GOUGING KIT WARNING ELECTRIC SHOCK can kill. • If the wire feeder is turned ON with the process switch in the gouging position, the welding output will turn ON. ------------------------------------------------------------------ When the gouging kit is installed, a rocker switch is used to select between wire feeder operation and gouging operation.

  • Page 45: Optional Kits And Accessories

    FLEX FEED™ 74 HT ACCESSORIES OPTIONAL KITS AND ACCESSORIES DRIVE ROLL AND WIRE GUIDE KITS Drive Roll Kits, Steel wires KP1505-030S .023-.030 (0.6-0.8mm) KP1505-035S .035 (0.9mm) KP1505-045S .045 (1.2mm) Includes: 4 Smooth V groove drive KP1505-052S .052 (1.4mm) rolls and inner wire guide. KP1505-1/16S 1/16 (1.6mm) KP1505-1 .035,.045 (0.9, 1.2mm)
  • Page 46 FLEX FEED™ 74 HT ACCESSORIES GUN ADAPTER KITS Description K3344-1 Gun Adapter Kit, Lincoln Back-end K3345-1 Gun Adapter Kit, standard #4 back-end K3346-1 Gun Adapter Kit, Magnum 500 #5 back-end K3347-1 Gun Adapter Kit, Miller back-end K3348-1 Gun Adapter Kit, Oxo back-end (requires K3345-1) K3349-1 Gun Adapter Kit,...
  • Page 47 FLEX FEED™ 74 HT ACCESSORIES CABLES Description Purpose Image K1797-xx Control Cable: Male 14 pin to Connects the user interface to Female 14 pin cable. the wire drive for boom systems. Connects the wire drive to the power source on bench systems. K2335-1,-2 Competitive Equipment Adapter Used to connect the Flex Feed...

  • Page 48: General Accessories

    FLEX FEED™ 74 HT ACCESSORIES GENERAL ACCESSORIES Description Purpose Image K3974-1 Gouging Contactor Kit Includes contactors and a switch to change electrode power from the feeder to a gouging torch. K1546-1 Incoming Bushing Use with .025 – 1/16” wires. for Lincoln Conduit. K1546-2 Incoming Bushing Use with 1/16”...
  • Page 49 FLEX FEED™ 74 HT ACCESSORIES Description Purpose Image K283 Portable Digital Wire Feed Speed Meter K3342-1 Standard Duty Wire For spools up to 44 lbs. Reel Stand K3343-1 Heavy Duty Wire Reel Stand For spools up to 44 lbs and coils up to 60 lbs. Includes K3341-1 Lift Bail.

  • Page 50: Routine Maintenance

    2. Remove the (4) screws holding the roof of the wire WARNING feeder to gain access to the pc board. 3. Turn power ON and trigger the Flex Feed 74 HT. ELECTRIC SHOCK can kill. 4. Set the WFS knob to 50 in/min and measure the drive •...

  • Page 51: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 52 4. The electrode is rusty or dirty. 4. Use only clean electrode. Use quality electrode, like L-50 or L-56 from Lincoln Electric. 5. The contact tip is partially melted 5. Replace the contact tip. or has spatter.
  • Page 53 FLEX FEED™ 74 HT TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION Wire feed speed consistently oper- 1. The jumper lead 20 tooth/30 tooth 1. Properly connect the jumper lead ates at the wrong value.
  • Page 54 FLEX FEED™ 74 HT DIAGRAMS...
  • Page 55 FLEX FEED™ 74 HT DIAGRAMS...
  • Page 56 FLEX FEED™ 74 HT DIAGRAMS...
  • Page 57 FLEX FEED™ 74 HT DIAGRAMS...
  • Page 58 NOTES FLEX FEED™ 74 HT...
  • Page 59 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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