Lincoln Electric 12442 Operator's Manual
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Lincoln Electric 12442 Operator's Manual

Lincoln Electric 12442 Operator's Manual

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Operator's Manual
LF-74 WIRE FEEDER
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10253
| Issue D ate Nov-17
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12442, 12443

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  • Page 1 Operator’s Manual LF-74 WIRE FEEDER For use with machines having Code Numbers: 12442, 12443 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) IM10253 | Issue D ate Nov-17...
  • 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 Remote Sense Lead Specifications..............
  • Page 7 TABLE OF CONTENTS Page Maintenance....................Section D Safety Precautions....................D-1 Routine........................D-1 Periodic........................D-1 Calibration Specification................D-1, D-2 ________________________________________________________________________ Troubleshooting......................E Safety Precautions....................E-1 How To Use Troubleshooting Guide..............E-1 Troubleshooting..................... E-2, E-3 ________________________________________________________________________ Wiring Diagram and Dimension Prints............Section F ________________________________________________________________________ Parts Lists.......................P-518 ________________________________________________________________________ LF-74...
  • Page 8 NOTES LF-74...

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS: LF-74 Wire Feeder SPEC.# WIRE FEED SPEED RANGE Model GMAW FCAW WFS Range Wire Sizes WFS Range Wire Sizes .023 – 1/16" .030 - 5/64” 50 – 800 ipm 50 – 800 ipm K2426-6 (0.6 – 1.6mm) (0.8 - 2.0mm) (1.27-20.3 m/min.) (1.27-20.3 m/min.)

  • Page 10: Safety Precautions

    INSTALLATION SAFETY PRECAUTION MOUNTING ELECTRIC SHOCK can kill. For location and size, LF-74 Bench Model Rear • Turn the input power OFF at the Mounting Holes (See Figure A.1) and for Bottom welding power source before instal- Mounting Holes (See Figure A.2). lation or changing drive rolls and/or guides.

  • Page 11: Bench Mount

    INSTALLATION BENCH MOUNT BOOM MOUNT The LF-74 mounts in a variety of configurations. As When boom mounting, remove the wire reel stand (if shipped from the factory, the LF-74 is suitable for assembled) and secure the wire feeder directly to the bench mounting or placing directly on top of the weld- desired surface.

  • Page 12: Weld Cable Sizes

    INSTALLATION 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 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.

  • Page 13: Coaxial Weld Cables

    INSTALLATION COAXIAL WELD CABLES A coaxial weld cable is constructed by 8 small leads wrapped around one large lead. The large inner lead Coaxial welding cables are specially designed welding connects to the electrode stud on the power source cables for pulse welding welding. Coaxial weld cables and the electrode connection on the wire feeder.
  • Page 14 INSTALLATION ANALOG CONTROL CABLE CONTROL CABLE CONNECTIONS K1797-xx 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 protec- tion. Connect the wire feeder only to power sources with overcurrent protection of no more than 15 amps.

  • Page 15: 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-74...

  • Page 16: Welding Gun/Wire Feeder Trigger Connector

    INSTALLATION WELDING GUN/WIRE FEEDER TRIGGER Drive Roll Kits, Cored Wires CONNECTOR Includes: 4 Knurled drive rolls and inner wire guide. KP1505-035C .030-.035" (0.8-0.9mm) Wire Feeder KP1505-045C .040-.045" (1.0-1.2mm) Amphenol KP1505-052C .052" (1.4mm) Welding G un KP1505-1/16C 1/16" (1.6mm) Trigger Lead Drive Roll Kits, Steel or Cored Wires Includes: 4 Knurled drive rolls and inner wire guide.

  • Page 17: Welding Guns, Torches And Accessories

    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.3a 11195, 11196, 11197 FIGURE A.3 for Codes 11610, 11611, FIGURE A.3a for Codes 12442, 12443 LF-74...

  • Page 18: Wire Drive Configuration

    INSTALLATION A-10 A-10 WIRE DRIVE CONFIGURATION 7. Disconnect the shielding gas hose from the gun bushing, if required. (See Figure A.5) 8. Connect the shielding gas hose to the new gun Changing the Gun Receiver Bushing bushing, if required. 9. Rotate the gun bushing until the thumb screw hole WARNING aligns with the thumb screw hole in the feed plate.

  • Page 19: Assembly Of Drive Rolls And Wire Guides

    INSTALLATION A-11 A-11 To install drive rolls and wire guides: ASSEMBLY OF DRIVE ROLLS AND WIRE (See Figure A.7 and A.7a) GUIDES 1. Turn off power at the welding power source. WARNING 2. Open pressure arms. ELECTRIC SHOCK can kill. 3.

  • Page 20: Pressure Arm Adjustment

    INSTALLATION A-12 A-12 PRESSURE ARM ADJUSTMENT WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before installation 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"...

  • Page 21: Shielding Gas Connection

    INSTALLATION A-13 A-13 SHIELDING GAS CONNECTION 6. Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting CYLINDER may explode if damaged. spring pressure is released. • Keep cylinder upright and chained 7. Standing to one side, open the cylinder valve slowly to support.

  • Page 22: Wire Reel Loading

    INSTALLATION A-14 A-14 WIRE REEL LOADING 3. Re-install the retaining collar. Make sure that the release bar snaps out and that the retaining collar WARNING fully engages the groove on the spindle. FIGURE A.10 • Keep hands, hair, clothing and tools away from rotating equipment.

  • Page 23: Weld Wire Routing

    INSTALLATION A-15 A-15 FIGURE A.11 WELD WIRE ROUTING The electrode supply may be either from reels, Readi- Reels, 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.

  • Page 24: Installing Electrode Conduit Kits

    INSTALLATION A-16 A-16 INSTALLING ELECTRODE CONDUIT KITS 3. Remove the six screws securing the wire drive panel to the sheet metal housing. 4. Loosen the set screw on the feed plate and remove WARNING the incoming bushing. FIGURE A.12a ELECTRIC SHOCK can kill. •...

  • Page 25: Aluminum Wire Preparations

    INSTALLATION A-17 A-17 ALUMINUM WIRE PREPARATIONS FIGURE A.13 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.
  • Page 26 INSTALLATION A-18 A-18 BASE MODEL (K2426-6) BENCH MODEL WITH HEAVY DUTY WIRE STAND (K2426-7) LF-74...

  • Page 27: Common Equipment Set-Ups

    INSTALLATION A-19 A-19 COMMON EQUIPMENT SET-UPS General Fabrication Description Item LF-74 Bench Model with Heavy Duty Wire Reel Stand K2426-7 .035, .045 (0.9mm, 1.2mm) Drive Roll Kit 10' (3m) Control Cable See welding gun literature Magnum Gun K586-1 Deluxe Regulator for Mixed Shielding Gases Shielding Gas Hose K1557-1 Swivel Kit...

  • Page 28: High Volume Production

    INSTALLATION A-20 A-20 HIGH VOLUME PRODUCTION Item Description LF-74, Base Model K2426-6 .035, .045 (0.9, .1.2mm) Drive Roll Kit 10' (3m) Control Cable. K1797-xx Control Cable Extension See Welding Gun Literature Welding Gun K2329-1 Remote Voltage Control Kit K2330-1 Timer Kit See Welding Arm Literature Welding Arm K586-1...

  • Page 29: Portable Welding

    INSTALLATION A-21 A-21 PORTABLE WELDING 3C, 4 Item Description See Welding Gun Literature Lincoln InnerShield Gun. K2329-1 Remote Voltage Control Kit. K2426-7 LF-74 Extra Torque Bench Model with Heavy Duty Wire Reel Stand 10' (3m) Control Cable. KPxxx .035, .045 (0.9, 1.2mm)Drive roll Kit K1797-xx Control Cable Extension.

  • Page 30: Operation

    OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SAFETY PRECAUTIONS Read this entire section of operating instructions COLD FEED before operating the machine. WARNING ELECTRIC SHOCK can kill. POSITIVE OUTPUT • Unless using cold feed feature, when NEGATIVE OUTPUT feeding with the gun trigger, the electrode and drive mechanism are...

  • Page 31: Product Description

    OPERATION PRODUCT DESCRIPTION General Functional Description The LF-74 fulfills the need for an economical wire feeder with a high performance wire drive. Functional General Physical Description features included are those that offer the most value – The LF-74 is optimized for GMAW and FCAW weld- a WFS knob with a calibrated printed scale, cold-feed/ ing.

  • Page 32: Front Panel Controls And Connections

    OPERATION FRONT PANEL CONTROLS AND CONNECTIONS CASE FRONT CONTROLS FIGURE B.1 ITEM DESCRIPTION Wire Feed Speed Knob. Location for Optional Remote Voltage Control (See Accessory Section For Kit Number). Location for Optional Burnback and Postflow Timer Kit (See Accessory Section For Kit Number). Thermal LED, Motor Overload.

  • Page 33: Wire Feed Speed Knob

    Always use quality electrode, such as L-50 or L-56 and prepares the end of the wire for the next arc from Lincoln Electric. start. Additional shielding gas protection is often required when welding aluminum, stainless steel or 5.

  • Page 34: 6. 2 Step - Trigger Interlock Switch

    OPERATION 6. 2 STEP - TRIGGER INTERLOCK SWITCH 7. GUN RECEIVER BUSHING (K1500-2) The 2 Step - Trigger Interlock switch (K1500-2 bushing is standard on all LF-74's) changes the function of the gun trigger. 2 This Gun Receiver Bushing is used with Lincoln gun Step trigger operation turns welding on connectors, also with Magnum 200/300/400 guns and and off in direct response to the trigger.

  • Page 35: Accessories

    ACCESSORIES OPTIONAL KITS: Includes: 10k potentiometer, K2329-1 Remote Voltage Control Kit. harness, knob and decal with a 0-10 scale and mounting hardware. Includes: Panel and harness K2330-1 Timer Kit. for adjusting burnback and postflow times. Includes: Wire Reel Stand for K2328-1 Standard Duty Wire Reel Stand.
  • Page 36 ACCESSORIES 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 Power Sources. cable for connecting a Lincoln 42 VAC wire feeder to a 24 VAC Miller power source.
  • Page 37 ACCESSORIES OPTIONAL KITS: K489-7 Gun Receiver Bushing (for Lincoln Includes: Gun receiver bush- Fast-Mate guns.) ing with trigger connector. K466-2 Magnum 200/300/400 to K1500-2 Includes: Gun adapter, cotter Adapter. pin, hex key wrench, wrench. K613-7 Magnum 550 to K1500-3 Adapter Includes: Trigger adapter, gun Lincoln Conduit.
  • Page 38 ACCESSORIES OPTIONAL KITS: Includes: Cover, backing K1634-1 Plastic Wire Cover for 30-44 lb. 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"...

  • Page 39: Maintenance

    MAINTENANCE MAINTENANCE Calibration of the LF-74 may be required when the p.c. board, potentiometer or motor is replaced or ser- Safety Precautions viced. Calibration matches the scale on the name plate to the actual wire feed speed. WARNING To verify the wire feed speed, ELECTRIC SHOCK can kill.
  • Page 40 MAINTENANCE 12442, To calibrate the wire feed speed for Codes 6. Set WFS Knob to 300 IPM. 12443 7. Measure drive role RPM. If reading is 54.8 to 56.0 RPM proceed to step 8 otherwise insert the short- Tools required: ing plug into the control p.c.

  • Page 41: Troubleshooting

    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 42: Troubleshooting

    TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE 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. 2.
  • Page 43 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Variable or "hunting" arc. 1. Check for proper size contact Tip. Make sure the contact tip is not worn, free of spatter and not melted. 2.
  • Page 44 DIAGRAMS LF-74...
  • Page 45 DIMENSION PRINTS BENCH MODEL 11.11 10.20 11.75 12.89 BENCH MODEL HEAVY DUTY 7.12 4.41 2.38 13.00 13.15 10.70 15.27 12.90 2.85 25.63 2.07 LF-74...
  • Page 46 Index of Sub Assemblies - 12443 P-518-A.jpg LF-74 (HD Bench Model) - 12443...
  • Page 47 Miscellaneous Items PART NUMBER DESCRIPTION 9ST15007-1 INERT ARC NUT 9ST15008 BRASS NIPPLE 9SS28198 DECAL LF-74 (HD Bench Model) - 12443...
  • Page 48 Miscellaneous Items No Image LF-74 (HD Bench Model) - 12443...
  • Page 49 Control Box, Center Panel & Case Shell Assembly PART NUMBER DESCRIPTION 9SL12100-4 CENTER PANEL & CASE SHELL ASBLY 9ST14882-4 BUMPER 9SS9225-49 THREAD FORMING SCREW (ROLLING) 9ST12380-1 BUSHING 9ST12380-3 BUSHING 9SS28276-2 CONTROL BOARD ASBLY 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SG4910-1 WIRING HARNESS 9SS12021-66 BOX RECEPTACLE SOLID SHELL 9ST10812-119 POTENTIOMETER...
  • Page 50 Control Box, Center Panel & Case Shell Assembly PART NUMBER DESCRIPTION 9SM22254 CONTROL CABLE ASSEMBLY 9ST14370-2 CONDUIT LOCKNUT 9SS8025-96 SELF TAPPING SCREW 9SS26587-3 CONTROL BOX PANEL 9SS23093-1 LED LENS CLEAR 9SS23094-1 RETAINING O RING 9SS21033-1 DOOR LATCH 9SCF000040 5/16-18X.75HHCS 9SE106A-3 LOCKWASHER 9SS9262-121 PLAIN WASHER...
  • Page 51 Control Box, Center Panel & Case Shell Assembly P-518-C.jpg LF-74 (HD Bench Model) - 12443...
  • Page 52 Wire Drive Assembly PART NUMBER DESCRIPTION 9SL12378-2 WIRE DRIVE ASBLY 9SL12091-1 GEARBOX MOUNTING PANEL 9SG4945-1 FEED PLATE ASBLY 9SL12283-1 IDLE ARM LEFT 9ST13942-14 DOWEL PIN 9SL12283-2 IDLE ARM RIGHT 9ST13942-14 DOWEL PIN 9SM19179-2 ADJUSTMENT ARM ASBLY 9ST9967-35 9SM19611-4 CONNECTOR BAR 9ST9447-112 SOCKET HEAD CAP SCREW 9SS9262-167...
  • Page 53 Wire Drive Assembly PART NUMBER DESCRIPTION 9SM20399 GEAR COVER CASTING 9SCF000012 1/4-20X.50HHCS 9SE106A-2 LOCKWASHER 9SS25638 DRIVE HUB ASBLY 9SS25308 TWIST LOCK RING 9SS25403 DRIVE HUB RETAINER 9SM18103-2 WIRE GUIDE-INNER KP1696-1 DRIVE ROLL KIT 035-045 0.9-1.2MM KP2071-1 WIRE GUIDE ASBLY OUTER 4 ROLL 9SS22905-2 GUN ADAPTER ASBLY 9ST13858...
  • Page 54 Wire Drive Assembly P-518-D.jpg LF-74 (HD Bench Model) - 12443...
  • Page 55 Wire Reel Stand & Base - K1524-3 PART NUMBER DESCRIPTION 9SL10229-3 Reel Stand & Base Assembly 9SM18320-2 BASE 9SM18745 MAST WELDED ASBLY 9SCF000062 5/16-18X1.00HHCS 9SS9262-121 PLAIN WASHER 9SE106A-14 LOCKWASHER 9SCF000029 5/16-18HN 9SS20979 RUBBER ISOLATOR 9SCF000034 3/8-16X.75HHCS 9SS9262-120 PLAIN WASHER 9SE106A-16 LOCKWASHER 9SS22523 CABLE CLAMP...
  • Page 56 Wire Reel Stand & Base - K1524-3 PART NUMBER DESCRIPTION 9SE106A-15 LOCKWASHER 9SS9262-121 PLAIN WASHER 9SE106A-3 LOCKWASHER 9SCF000040 5/16-18X.75HHCS LF-74 (HD Bench Model) - 12443...
  • Page 57 Wire Reel Stand & Base - K1524-3 P-518-E.jpg LF-74 (HD Bench Model) - 12443...
  • Page 58 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 59 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 60 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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