SVM171-A: Service Manual

SVM171-A
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January, 2007
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LF-72/74
For use with machines having Code Number : 11075 thru 11293
Safety Depends on You

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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,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
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SERVICE MANUAL
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Copyright © 2007 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
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i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

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. cancer, 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 & 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. 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 posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95

ii ii
Return to Master TOC SAFETY
ELECTRIC SHOCK can kill. ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5. b. The operation of welding fume control equipment is affected
damaged insulation.
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling.
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-

3.h. Never simultaneously touch electrically “hot” parts of
cally thereafter to be certain it is within applicable OSHA PEL
electrode holders connected to two welders because voltage
and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect
The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
5.d. 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.
5.e. 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.
5.f. Also see item 1.b.
AUG 06

iii iii
Return to Master TOC SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95

iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
a. Les circuits à l’électrode et à la piéce sont sous tension la zone de travail qu’il est pratique de le faire. Si on place la
quand la machine à souder est en marche. Eviter toujours masse sur la charpente de la construction ou d’autres endroits
tout contact entre les parties sous tension et la peau nue éloignés de la zone de travail, on augmente le risque de voir
ou les vétements mouillés. Porter des gants secs et sans passer le courant de soudage par les chaines de levage,
trous pour isoler les mains. câbles de grue, ou autres circuits. Cela peut provoquer des
b. Faire trés attention de bien s’isoler de la masse quand on risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher met- câbles jusqu’à ce qu’ils se rompent.
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble de galvanisées plombées, ou cadmiées ou tout autre métal qui
soudage et la machine à souder en bon et sûr état defonc- produit des fumeés toxiques.
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut être le total ou autres produits irritants.
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
courant pour soudage semi-automatique, ces precautions le code “Code for safety in welding and cutting” CSA Standard
pour le porte-électrode s’applicuent aussi au pistolet de W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie du
PRÉCAUTIONS DE SÛRETÉ POUR
corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou 1. Relier à la terre le chassis du poste conformement au code de
quand on regarde l’arc. l’électricité et aux recommendations du fabricant. Le dispositif
b. Porter des vêtements convenables afin de protéger la peau de montage ou la piece à souder doit être branché à une
de soudeur et des aides contre le rayonnement de l‘arc. bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 3. Avant de faires des travaux à l’interieur de poste, la debranch-
de l’huile, tels que les gants en cuir, chemise épaisse, pan- er à l’interrupteur à la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93

v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv
Installation LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Installation LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section AA
Operation LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operation LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BB
Accessories LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Accessories LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section CC
Maintenance LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Maintenance LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DD
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P501 Series (LF-72)

P518 Series (LF-74)
LF-72/74

Section A-1 TABLE OF CONTENTS Section A-1
- INSTALLATION SECTION -
Installation ..............................................................................................................Section A
Technical Specifications...............................................................................................A-2
Safety Precautions .......................................................................................................A-3
Location ..................................................................................................................A-3
Mounting .................................................................................................................A-3
Bench Mount ..........................................................................................................A-4
Swivel Mount ..........................................................................................................A-4
Boom Mount ...........................................................................................................A-4
Suspended..............................................................................................................A-4
Weld Cable Sizes ....................................................................................................A-5
Coaxial Weld Cables...............................................................................................A-6
Weld Cable Connections ........................................................................................A-6
Analog Control Cable Connections..............................................................................A-7
Analog Miller Control Cable Adapter ...........................................................................A-8
Welding Gun/Wire Feeder Trigger Connector.........................................................A-9
High Frequency Protection .....................................................................................A-9
Remote Sense Lead Specifications........................................................................A-9
Wire Drive Systems ......................................................................................................A-9
Welding Guns, Torches and Accesories ....................................................................A-10
Procedure for Changing Drive and Idle Roll Sets ......................................................A-11

Wire Drive Configuration..............................................................................A-11/A-12
Pressure Arm Adjustment .....................................................................................A-12
Wire Reel Loading.................................................................................................A-13
Weld Wire Routing ................................................................................................A-14
Sheilding Gas Connections........................................................................................A-15
Installing Electrode Conduit Kits ................................................................................A-16
Aluminum Wire Preperations......................................................................................A-17
Base Model, Bench Model Standard Duty and Bench Model Heavy Duty...............A-18
Typical System Configurations...................................................................................A-19
LF-72/74 SINGLE/DUAL

A-2 INSTALLATION A-2
TECHNICAL SPECIFICATIONS: LF-72 Wire Feeder

Return to Section TOC
SPEC.# TYPE WIRE FEED SPEED RANGE

Wire Size
LF-72 Speed Solid Cored
K2327-1 Base Model

K2327-4
K2327-2 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)
K2327-3 Bench Mode
Heavy Duty
CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS
SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING
Input Voltage Dimensions
and Current Height Width Depth Weight Operating Storage
43 Lbs
K2327-1 LF-72 11.1“ 10.2“ 12.9“ (19.7 Kg.)
( 282 mm) (259 mm) (328 mm)

K2327-4 Base Model 26.5 Lbs
(12.0 Kg)
Dimensions ∆
Height Width Depth Weight
LF-72
K2327-2 24-42VAC 12.6“ 10.9“ 22.5“ 52.5 Lbs 14°F to 104°F -40°F to 85°F
Bench 9 AMPS ( 320 mm) (277 mm) (572 mm) (23.8 Kg.) (-10°C to 40°C) (-40°C to 85°C)
Standard
Duty
Dimensions ∆
LF-72
K2327-3 15.3“ 13.0“ 27.7“ 67.5 Lbs
Bench ( 389 mm) (330 mm) (704 mm) (30.6 Kg.)
Heavy
Duty
WELDING CAPACITY RATING

Amp Rating Duty Cycle

500 A 60%
400 A 100%
∆ Dimensions do not include wire reel.
LF-72/74

SAFETY PRECAUTION MOUNTING

ELECTRIC SHOCK can kill. For location and size, LF-72 Bench Model Rear
• Only qualified personnel should Mounting Holes (See Figure A.1) and for Bottom
perform this installation.
Mounting Holes (See Figure A.2).
• 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 FIGURE A.1
connected to the welding system at
the disconnect switch or fuse box
before working on this equipment.
• 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.

FIGURE A.2
LF-72/74

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).
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
Swivel Kit and Base Model LF-72 must not be used unless insulation is provided
between the wire feeder enclosure and the hanging
device.
------------------------------------------------------------------------
LF-72/74

SAFETY PRECAUTION
ELECTRIC SHOCK can kill.

• Only qualified personnel should

input power to any other equipment

----------------------------------------------------------------------
WELD CABLE SIZES

Table A.1 has the copper cable sizes recommended for

different currents and duty cycles. Lengths stipulated
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 minimizing
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
61 to 76 m
Amperes Cycle 0 to 15 m 15 to 31 m 31 to 48 m 48 to 61 m
200 60 2 2 2 1 1/0
200 100 2 2 2 1 1/0
225 20 4 or 5 3 2 1 1/0
225 40 & 30 3 3 2 1 1/0
250 30 3 3 2 1 1/0
250 40 2 2 1 1 1/0
250 60 1 1 1 1 1/0
250 100 1 1 1 1 1/0
300 60 1 1 1 1/0 2/0
325 100 2/0 2/0 2/0 2/0 3/0

350 60 1/0 1/0 2/0 2/0 3/0
400 60 2/0 2/0 2/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
500 60 2/0 2/0 3/0 3/0 4/0
** 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-72/74

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 or STT welding. Coaxial weld and the electrode connection on the wire feeder. The
cables feature low inductance, allowing fast changes in small leads combine together to form the work lead,
the weld current. Regular cables have a higher induc- one end attached to the power source and the other
tance which may distort the pulse or STT wave shape. end to the work piece. (See Coaxial weld Cable below.)
Inductance becomes more severe as the weld cables
become longer. 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
Coaxial weld cables are recommended for all pulse
to metal electrical contact. Poor work lead connections
and STT welding, especially when the total weld cable
can result in poor welding performance.
length (electrode cable + work cable) exceeds 50 feet
(7.6m)
Work
Electrode
Work
Power Source
Work Electrode Wire Feeder

Coaxial Weld Cable
Electrode
Work
LF-72/74

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 protection.

Connect the wire feeder only to power sources with
overcurrent protection of no more than 15 amps.
POWER SOURCE WIRE FEEDER

J A A J
I K B B K I
H N L C C L N H
G M M G
D D
F E E F
PIN FUNCTION LEAD#
A Unused -------
B Reserved -------
C Welding Output Control 2
(trigger from feeder)
D Welding Output Control 4

E Remote Voltage Control 77
(“+” supply from feeder or remote)
F Remote Voltage Control 76
(control signal from feeder or remote)
G Remote Voltage Control 75
(“-” supply from feeder or remote)
H Reserved
I 42 VAC 41
J Reserve for Future Use.
K 42 VAC 42
L Reserve for Future Use.
M Unused -------
N 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-72/74

A-8 NOTES A-8
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.
J A A J
I K B B K I
H N L C C L N H
G M D D M G
F E E F
MILLER POWER SOURCE LINCOLN WIRE FEEDER
Pin Function Pin Function
A 24 VAC to feeder I 42 VAC feeder

D Welding Output Control
B Welding Output Control C Welding Output Control

C +10VDC to feeder for remote control E Remote Voltage Control ("+" supply, from
power source)
D Remote control common G Remote Voltage Control ("-" supply, from
power source)
E 0-10VDC from feeder for remote control. F Remote Voltage Control (control signal from
feeder or remote.)
F Current feedback to feeder. J Reserved for future use.
Scaled 0-10V. 1 V = 100 amps.
Referenced to pin D.
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.
I
J
K
L
M
N N Electrode voltage to power source (67)
Miller is a registered trademark not owned or licensed by The Lincoln Electric Company.
LF-72/74

WELDING GUN/WIRE FEEDER TRIGGER REMOTE SENSE LEAD SPECIFICATIONS

CONNECTOR
Wire Feeder Refer to the power source instruction manual for
Amphenol instructions for connecting the wire feeder for STT
E
welding.
A D
Welding G un
WIRE DRIVE SYSTEMS
B C Trigger Lead 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 the fol-
Wire Feeder lowing tables:
Pin Function
A Gun Trigger Drive Roll Kits, Steel Wires
B - Includes: 2 Smooth V groove drive rolls and an inner
C Common wire guide.
D -
E - KP1696-030S .023-.030 (0.6-0.8mm)

KP1696-035S .035 (0.9mm)
HIGH FREQUENCY PROTECTION KP1696-045S .045 (1.2mm)
KP1696-052S .052 (1.4mm)
Locate the LF-72 away from radio controlled machin- KP1696-1/16S 1/16 (1.6mm)
ery. The normal operation of the LF-72 may adversely KP1696-1 .035, .O45 (0.9, 1.2mm)
affect the operation of RF controlled equipment, which KP1696-2 .040 (1.0mm)
may result in bodily injury or damage to the equipment
Drive Roll Kits, Cored Wires
Includes: 2 Knurled drive rolls and an inner wire guide.
KP1697-035C .030-.035" (0.8-0.9mm)

KP1697-045C .040-.045" (1.0-1.2mm)
KP1697-052C .052" (1.4mm)
KP1697-1/16C 1/16" (1.6mm)
KP1697-068 .068-.072" (1.7-1.8mm)
KP1697-5/64C 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 .035" (0.9 mm)

KP1695-040A .040" (1.0mm)
KP1695-3/64A 3/64" (1.2mm)
KP1695-1/16A 1/16" (1.6mm)
DRIVE ROLLS
INNER WIRE
GUIDE
LF-72/74

WELDING GUNS, TORCHES AND ACCES- 3. Fully insert the gun cable connector end into the
SORIES gun receiver bushing and gently tighten the thumb

screw as show in Figure A.3 below.
GUN RECEIVER BUSHING
4. Connect the gun trigger connector to the trigger
The LF-72 wire feeder comes with a K1500-2 gun
receptacle. Make sure that the key ways are
receiver bushing.
aligned and insert.
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) long Magnum 400 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
LF-72 BASE MODEL
TRIGGER RECEPTACLE

(INTERCHANGABLE)
WIRE DRIVE UNIT
GUN HANDLE GUN TUBE

GUN NOZZLE
GUN AND CABLE
GUN TRIGGER
CONNECTOR
CABLE CONNECTOR
END K466-10
LF-72/74

PROCEDURE FOR CHANGING WIRE DRIVE CONFIGURATION

DRIVE AND IDLE ROLL SETS (See Figure A.5)

Changing the Gun Receiver Bushing
(See Figure A.4 )
WARNING
WARNING
• Turn the input power OFF at the dis-
connect switch or fuse box before
• Turn the input power OFF at the
attempting to connect or disconnect
welding power source before instal-
input power lines, output cables or
lation or changing drive rolls and/or
control cables.
guides.
• Only qualified personnel should perform this
• Do not touch electrically live parts.
installation.
• When inching with the gun trigger, electrode and
------------------------------------------------------------------------
drive mechanism are "hot" to work and ground
Tools required:
and could remain energized several seconds
• 1/4" hex key wrench
after the gun trigger is released.
Note: Some gun bushings do not require the use of
• Only qualified personnel should perform mainte-
the thumb screw.

nance work.
-----------------------------------------------------------------------
1. Turn power off at the welding power source.
-
2. Remove the welding wire from the wire drive.
2. Release the idle roll pressure arm.
3. Remove the outer wire guide by turning the knurled
3. Remove the thumb screw from the wire drive.
thumbscrews counter-clockwise to unscrew them
from the feed plate.
4. Remove the welding gun from the wire drive.
4. Rotate the triangular lock and remove the 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 preci-
sion fit, light tapping may be required to remove the

gun bushing.
rolls. FIGURE A.4
5. Remove the inner wire guide. FIGURE A.5
6. Insert the new inner wire guide, groove side out,
over the two locating pins in the feed plate.
THUMB SCREW
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 GUN RECEIVER BUSHING
pins and tightening the knurled thumbscrews.

9. Close the idle arm and engage the idle roll pressure OUTER WIRE GUIDE
arm. Adjust the pressure appropriately.
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN TIGHTEN
LF-72/74

7. Disconnect the shielding gas hose from the gun PRESSURE ARM ADJUSTMENT
bushing, if required.
WARNING
8. Connect the shielding gas hose to the new gun
bushing, if required. ELECTRIC SHOCK can kill.
9. Rotate the gun bushing until the thumb screw hole • Turn the input power OFF at the
aligns with the thumb screw hole in the feed plate. welding power source before instal-
Slide the gun receiver bushing into the wire drive lation or changing drive rolls and/or
and verify the thumb screw holes are aligned. guides.
10. Tighten the socket head cap screw. • When inching with the gun trigger, electrode and
11. Insert the welding gun into the gun bushing and and could remain energized several seconds
tighten the thumb screw. after the gun trigger is released.
Gun Receiver For use With
nance work.
Bushing
------------------------------------------------------------------------
The pressure arm controls the amount of force the
K1500-1 K466-1 Lincoln gun connectors;
drive rolls exert on the wire. Proper adjustment of the
Innershield and Subarc guns)
pressure arm gives the best welding performance.
K1500-2 K466-2, K466-10 Lincoln gun
Set the pressure arm as follows (See Figure A.6):
connectors; Magnum 200/300/400
Aluminum wires between 1 and 3
guns and compatible with Tweco®
Cored wires between 3 and 4
#4)
Steel, Stainless wires between 4 and 6
FIGURE A.6
Magnum 550 guns and compatible
with Tweco® #5)

compatible with Miller® guns.)
K1500-5 (Compatible with Oxo® guns.)
K489-7 ( Lincoln Fast-Mate guns.)
CORED WIRES SOLID WIRES
OUTERSHIELD
12 ALUMINUM
METALSHIELD
INNERS HIELD
34
STEEL
56 STAINLE SS
LF-72/74

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.8
• Keep hands, hair, clothing and tools away from
rotating equipment. Retaining
• Do not wear gloves when threading wire or Collar
changing wire spool.
• Only qualified personnel should install, use or
service this equipment.
-----------------------------------------------------------------------
Loading 10 to 15 lb. (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 Loading 30 lb. (13.6 kg) Readi-Reels
adapter for loading 2-1/2" (64mm) wide spools. (See (See Figure A.9)
figure A.7 and figure A.8)

A K363-P Readi-Reel adapter is required for loading

1. Squeeze the release bar on the retaining collar and these spools on 2" (51mm) spindles.
remove it from the spindle.
2. Place the spindle adapter on the spindle, aligning 1. Squeeze the release bar on the retaining collar and
the spindle brake pin with the hole in the adapter. remove it from the spindle.
3. Place the spool on the spindle and align the adapter 2. Place the Readi-Reel adapter on the spindle, align-
brake tab with one of the holes in the back side of ing the spindle brake pin with one of the holes in the
the spool. An indicator mark on the end of the spin- adapter.
dle shows the orientation of the brake tab. Be cer- 3. Re-install the retaining collar. Make sure that the
tain the wire feeds off of the spool in the proper release bar snaps out and that the retaining collar
direction. fully engages the groove on the spindle.
4. Re-install the retaining collar. Make sure that the 4. Rotate the spindle and adapter until the retaining
release bar snaps out and that the retaining collar spring is at the 12 o’clock position.
fully engages the groove on the spindle.
FIGURE A.7 5. Position the Readi-Reel so that electrode de-reels in
the proper direction.
Adapter 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.
Spindle Placement
The wire reel stand provides two mounting locations Removing a Readi-Reel
for the spindle. Each mounting location consists of a
tube in the center of the mast and locating slots. 1. To remove a Readi-Reel from the an adapter,
depress the retaining spring with a thumb while
Loading 16 to 44 lb. (7.3 – 20kg) Spools pulling the Readi-Reel cage from the adapter with
(See figure A.8) both hands. Do not remove the adapter from the
spindle.
1. Squeeze the release bar on the retaining collar and

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 shows the orientation of the brake holding pin.
Be certain the wire feeds off of the spool in the prop-
er direction.
LF-72/74

FIGURE A.9
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 minimum,
and also that the force required to pull the wire

from the reel into the wire drive unit is kept at a
minimum.
b) The electrode is “hot” when the gun trigger is

pressed and must be insulated from the boom and
structure.
c) 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-72/74

SHIELDING GAS CONNECTION 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
CYLINDER may explode if damaged.
union nuts with a wrench.
• Keep cylinder upright and chained to
6. Before opening the cylinder valve, turn the regulator
support.
adjusting knob counterclockwise until the adjusting
• Keep cylinder away from areas where
spring pressure is released.
it may be damaged.
• Never lift welder with cylinder attached.
7. Standing to one side, open the cylinder valve slowly
• Never allow welding electrode to touch cylinder.
a fraction of a turn. When the cylinder pressure gage
• Keep cylinder away from welding or other live
stops moving, open the valve fully.
electrical circuits.
------------------------------------------------------------------------
8. The flow regulator is adjustable. Adjust it to the flow
BUILD-UP OF SHIELDING GAS may
rate recommended for the procedure and process
harm health or kill.
being used before making a weld.
• 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 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% CO2 cylinder, insert reg-
ulator adapter between regulator and cylinder valve.
If adapter is equipped with a plastic washer, be sure
it is seated for connection to the CO2 cylinder.
LF-72/74

INSTALLING ELECTRODE (For Codes 11209, 11210, 11211 and above)

To install Lincoln conduit: (See Figure A.10b)

CONDUIT KITS
WARNING 2. Remove the “O” ring holding the ball bushing

assembly to the back of the wire feeder. Remove
the ball bushing assembly.
• Turn the input power OFF at the dis- FIGURE A.10b
connect switch before working on
this equipment.
------------------------------------------------------------------------
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 "O" RING
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. 3. Place a K1546-xx conduit connector into the back of
the wire drive. Rotate the conduit connector to a
2. Remove the snap ring holding the ball bushing position where the thumb screw does not interfere
assembly to the back of the wire feeder. Remove with the idle arm or door.
the ball bushing assembly. 4. Tighten the set screw to secure the conduit connec-
tor in the wire drive.
FIGURE A.10a
5. Insert conduit through the sheet metal of the LF-72
and into the conduit connector. Secure with the
thumb screw.
FIGURE A.11
LF-72/74

ALUMINUM WIRE PREPARATIONS FIGURE A.12a

(For Codes 11209, 11210, 11211 and above)

WARNING Tools required: (See Figure A.12b)
• 9/64" Hex key wrench
• Turn the input power OFF at the dis- 1. Turn off power at the welding power source.
this equipment. 2. Remove the snap ring holding the ball bushing
• Do not touch electrically hot parts. assembly to the back of the wire feeder. Remove the
ball bushing assembly.
------------------------------------------------------------------------
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.
"O" RING
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
1. Turn off power at the welding power source. FIGURE A.12b
2. Remove the snap ring holding the ball bushing 3. Remove the three socket head cap screws from the
assembly to the back of the wire feeder. Remove the ball bushing assembly. Caution: as the screws are
ball bushing assembly. being loosened, the balls may fall free from the
assembly. 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-72/74

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-18

BASE MODEL
LF-72/74
INSTALLATION
BENCH MODEL HEAVY DUTY

BENCH MODEL STANDARD DUTY
A-18
TYPICAL SYSTEM CONFIGURATIONS

The LF-72 is capable of welding with many different welding processes. These processes may require reconfig-
uring the LF-72 with other products that may or may not be included with the model you purchased. Use the Table
1 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. Description Wire Gun Wire Reel Stand Drive Roll Kit CONTROL
Feeder CABLE
K2327-1 Base Model ---
K2327-2 Bench Model, Standard duty, up to

Standard Duty 15', Magnum 400, 44 lb. (20 kg)spools. .035-.045 combo
LF-72 .035-.045 (0.9-1.2 mm) (0.9-1.2 mm) 10’ (3m)
K2327-3 Bench Model, Heavy Duty, up to
Heavy Duty 60 lb. (27.2 kg) coils.
K2327-4 Base Model --- --- ---

LF-72/74

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-20

LF-72/74
NOTES
A-20
Section B-1 TABLE OF CONTENTS Section B-1
- OPERATION SECTION -
Operation ................................................................................................................Section B
Safety Precautions .......................................................................................................B-2

Graphic Symbols..........................................................................................................B-2
Common Welding Abbreviations..................................................................................B-3
Product Description......................................................................................................B-3
Recommended Processes and Required Equipment ..................................................B-3
Front Panel Controls and Connections ........................................................................B-4
1. Remote Voltage Control Kit (Optional)................................................................B-5
2. Burnback and Postflow Timer Kit (Optional) ......................................................B-5

3. Thermal LED, Motor Overload ............................................................................B-5
4. Cold Feed/Gas Purge Switch .............................................................................B-5
5. 2 Step - Trigger Interlock Switch.................................................................B-5/B-6
6. Wire Feed Speed Knob ......................................................................................B-6
7. Gun Receiver Bushing ........................................................................................B-6
8. Trigger Connector 5-Pin Amphenol ....................................................................B-6

B-2 OPERATION B-2
SAFETY PRECAUTIONS The serviceability of a product or structure utilizing

the LF-72 wire feeder is and must be the sole respon-

Read this entire section of operating instructions sibility of the builder/user. Many variables beyond
before operating the machine. the control of The Lincoln Electric Company affect the
results obtained in using the LF-72 wire feeder.
WARNING These variables include, but are not limited to, weld-
ing procedure, plate chemistry and temperature,
weldment design, fabrication methods and service
ELECTRIC SHOCK can kill. requirements. The available range of the LF-72 wire
feeder may not be suitable for all applications, and
• Unless using cold feed feature, when the builder/user is and must be solely responsible for
feeding with the gun trigger, the welding settings.
electrode and drive mechanism are
always electrically energized and
could remain energized several sec-
onds after welding ceases. GRAPHIC SYMBOLS THAT APPEAR ON
• Do not touch electrically live parts or electrodes THIS MACHINE OR IN THIS MANUAL
with your skin or wet clothing.
• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.
COLD FEED
-------------------------------------------------------------
ONLY QUALIFIED PERSONS SHOULD INSTALL,
USE OR SERVICE THIS EQUIPMENT. READ AND POSITIVE OUTPUT
FOLLOW THE MANUFACTURER’S INSTRUC-
TIONS, EMPLOYER’S SAFETY PRACTICES AND
MATERIAL SAFETY DATA SHEETS (MSDS) FOR NEGATIVE OUTPUT
CONSUMABLES.
-----------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF & PROTECTIVE
OTHERS. GROUND
FUMES AND GASES can be
dangerous. WARNING OR
CAUTION
• Keep your head out of fumes.

• Use ventilation or exhaust at the arc, DANGEROUS
or both, to keep fumes and gases
from your breathing zone and gener-
VOLTAGE
al area.
SHOCK
HAZARD
WELDING SPARKS can cause
fire or explosion.
WELDING
• Do not weld near flammable material. FUMES
• Do not weld on containers which have held flam-
mable material.
EXPLOSION
ARC RAYS can burn.
• Wear eye, ear, and body protection.

GAS INPUT
-----------------------------------------------------------
Observe additional guidelines detailed in the WORK
beginning of this manual. CONNECTION
LF-72/74

B-3 OPERATION B-3
PROCESS LIMITATIONS
COMMON WELDING ABBREVIATIONS

• Rated for up to 1/16(1.6 mm) solid electrode and 5/64
WFS (2.0 mm) cored electrode.
• Wire Feed Speed • The maximum WFS is 800 in/min (20.3 M/min).
• The LF-72 is not recommended for GMAW-Pulse
CV (synergic), GTAW, GTAW-Pulse, SAW, CAG, SMAW.
• Constant Voltage • Do not use push-pull equipment with the LF-72.
• For K2327-2 Bench model, std. duty: Maximum
GMAW (MIG) spool size = 44 lb. (20 kg); 12 inch (300mm) diame-
• Gas Metal Arc Welding ter; 4 inch (100mm)
• For K2327-3 Bench model, heavy duty: Maximum
FCAW (Cable Innershield or Outershield) spool size = 60 lb. (27.2 kg)
• Flux Core Arc Welding
REQUIRED EQUIPMENT
PRODUCT DESCRIPTION
Lincoln’s LF-72 is designed for use with the CV and DC
General Physical Description
family of power sources. These include:
The LF-72 is optimized for .035 through .045 (0.9mm • CV-305 • DC-400
through 1.2mm) GMAW welding. The powerful 2 roll • CV-400 • DC-600
drive, heavy duty enclosure and wire reel stand com- • CV-655 • Invertec™ V350
bine to make an easy to install, easy to use wire feed- • Invertec™ V450
er for everyday welding. Powering the wire drive is a
high performance motor gearbox. A heavy duty hinged EQUIPMENT LIMITATIONS
door opens easily, which provides an ample amount of
room for assembling precision drive components and • Maximum gun length =25 ft. (7.6m)
the welding gun. Also under the door is a convenient • Maximum conduit length = 30 ft. (9.1m)
storage tray for contact tips and tools. • Maximum total control cable length = 100ft (31m)
• The LF-72 operates on 42VAC and not 115 VAC
Three packages are available. The basic unit consists • The K1733-1 wire straightener may not be used with
of the wire drive box housing. The standard duty bench the LF-72
model targets users of 12" (305 mm)diameter spools. • Gun bushings are required for welding guns that do
The heavy duty bench model satisfies the needs of not have a Magnum (Tweco #2-#4 compatible) back
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. Easy to use features are a cali-
brated WFS knob, cold-feed/ gas purge switch and
trigger interlock.
• Several kits are available to expand the LF-72’s weld-

ing capability. The timer kit allows adjustment of burn-
back and postflow times. The remote voltage control
kit includes a 0 to 10 dial for setting the welding volt-
age 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 .023-1/16 (0.6 - 1.6 mm) steel electrodes.
• FCAW .035 -5/64 (0.9 - 2.0mm) cored electrodes
LF-72/74

B-4 OPERATION B-4
FRONT PANEL CONTROLS AND CONNECTIONS

FIGURE B.1 CASE FRONT CONTROLS
2
8
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 up to feed wire with weld output off.
Press the switch down for gas flow with weld output off.
5 2 step - Trigger Interlock switch.
6 Wire Feed Speed Knob.
7 Gun Receiver Bushing.

8 Trigger Connector 5-pin amphenol for connecting the MIG gun trigger. See Installation Section
for detail.
LF-72/74

B-5 OPERATION B-5
1. REMOTE VOLTAGE CONTROL KIT 3. THERMAL LED, MOTOR OVERLOAD

The optional remote voltage control kit adjusts the The thermal light illuminates when the wire drive
arc voltage from the minimum to the maximum volt- motor draws too much current. If the thermal light illu-
age of the welding power source. Rotate the knob minates, the wire drive will automatically shutdown for
counterclockwise to reduce the arc voltage and rotate up to 30 seconds to allow the motor to cool. To start
the knob clockwise to raise the arc voltage. 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

2. BURNBACK AND POSTFLOW TIMER KIT spring centered toggle switch.
The optional Burnback and Postflow Timer Kit gives
control over the shielding gas at the end of the weld To activate Cold Feeding, hold the switch
and prepares the end of the wire for the next arc start. in the UP position. The wire drive will
Additional shielding gas protection is often required feed electrode but neither the power
when welding aluminum, stainless steel or exotic source nor the gas solenoid will be ener-
alloys. gized. Adjust the speed of cold feeding
by rotating the WFS knob. Cold feeding,
When stitch welding, set the postflow time to maxi- or "cold inching" the electrode is useful
mum for best results. for threading the electrode through the gun.
Burnback Timer Hold with toggle switch in the DOWN position to acti-
The burnback timer range is OFF to 0.25 seconds. vate Gas Purge and let the shielding gas flow. The
The burnback timer controls the additional amount of gas solenoid valve will energize but neither the power
time the power source output remains ON after the source output nor the drive motor will be turned on.
The Gas Purge switch is useful for setting the proper
wire drive has stopped feeding wire. Burnback

adjustment prevents the wire from sticking to the weld flow rate of shielding gas. Flow meters should always
at the end of a weld and helps to condition the wire for be adjusted while the shielding gas is flowing.
the next weld.
5. 2 STEP - TRIGGER INTERLOCK SWITCH
To set the burnback time, adjust the knob to approxi- The 2 Step - Trigger Interlock switch
mately 0.03 seconds and then decrease or increase changes the function of the gun trigger. 2
the time as desired. Step trigger operation turns welding on
and off in direct response to the trigger.
Trigger Interlock operation allows welding
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
Postflow Timer 2 Step trigger operation is the most common. When

The postflow timer range is OFF to 10 seconds. the gun trigger is pulled, the welding power source
Postflow is the time from when the power source out- energizes the electrode output and the wire feeder
put turns OFF until the postflow timer expires. Use feeds wire for welding. The power source and wire
postflow to protect the weld while the weld cools. feeder continue welding until the trigger is released.

B-6 OPERATION B-6
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 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-72/74

Section C-1 TABLE OF CONTENTS Section C-1
- ACCESSORIES SECTION -
Accessories ............................................................................................................Section C
General Options / Accessories .............................................................................C-2/C-5


C-2 ACCESSORIES C-2
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. up to 44 lbs (20 kg) spools,
Spindle and mounting hard-
ware.
K2331-1 Lift Bail Kit. Includes: Insulated lift bail

and hardware.
K2332-1 Swivel Kit. Includes: Swivel adapter and

(for use with Standard Duty Bench mounting hardware for attach-
Models) ing to a power source lift bale.
Includes: Coaxial weld cable

of length "xx". Ends of the
K1796-xx Co-Axial Power Cable. 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
K1803-1 Work and Feeder Cables Ground Clamp, and Twist-

Package. 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".
Includes: Twist-Mate to Twist-

Mate, 1/0 Cable for 25' (7.6m)
K1841-xx Weld Power Cable, cables.
Twist-Mate to Twist-Mate. 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
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-72/74

C-3 ACCESSORIES C-3
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.
Includes: One transformer kit

K1520-1 42 Volt Transformer Kit. for operating a 42 VAC wire
feeder on a power source
supplying 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.
Gun Receiver Bushing (for guns Includes: Gun receiver bush-

K1500-1 with K466-1 Lincoln gun connec- ing, set screw and hex key
tors; Innershield and Subarc wrench.
guns.)
Includes: Gun receiver bush-
Gun Receiver Bushing (for guns with
K1500-2 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.)

K1500-3 with K613-7 Lincoln gun connec- ing with hose nipple, set
tors; Magnum 550 guns and com- screw and hex key wrench.
patible with Tweco® #5.)
Gun Receiver Bushing (for gun Includes: Gun receiver bush-

with K466-3 Lincoln gun connec-
K1500-4 ing with hose nipple, set
tors; compatible with Miller®
guns.) screw and hex key wrench.

K1500-5 Gun Receiver Bushing (compatible ing with hose nipple, 4 guide
with Oxo® guns.) tubes, set screw and hex key
wrench.
LF-72/74

C-4 ACCESSORIES C-4
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. adapter and hex key wrench.
K1546-1 Incoming Bushing, for Lincoln Includes: Incoming bushing

Conduit .025- 1/16" (0.6 - 1.6mm) and hex key wrench.
wire.

Conduit 1/16-1/8" (1.6 - 3.2 mm ) and hex key wrench.

wire.
K435 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. (Electrode not included.)
K468 Spindle Adapter, for mounting 8in Includes: Spindle Adapter.

(203mm) diameter spools on 2 in
(51 mm) spindles.
K363P Readi-Reel Adapter, for mounting Includes: Readi-Reel spool

23-30 lb. (10.4 - 13.6 kg) reels to 2 adapter. (Spool of electrode
in (51 mm) spindles. not included.)
K438 Readi-Reel Adapter, for mounting Includes: Readi-Reel spool

50-60 lb. (22.7 - 27.2 kg) reels to adapter. (Spool of electrode

2 in (51 mm) spindles. For use not included.)
with Heavy Duty Bench models.
Coil Adapter, for mounting 50-60

K1504-1 lb. (22.7 - 27.2 kg) coils to 2 in (51 Includes: 50-60 lb. (22.7 -
mm) spindles. 27.2 kg) coil adapter.
For use with heavy Duty Bench
LF-72/74

C-5 ACCESSORIES C-5
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" - 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 lb.

(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 lb. 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, brackets and
mounting hardware.
Insulated Lift Bail Includes: Insulated Lift Bail

K1555-1 (for use with Heavy Duty Bench and mounting hardware.
Models)
LF-72/74

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-6

LF-72/74
NOTES
C-6
Section D-1 TABLE OF CONTENTS Section D-1
- MAINTENANCE SECTION -
Maintenance ...........................................................................................................Section D
Safety Precautions ........................................................................................................D-2

Routine Maintenance.....................................................................................................D-2
Periodic Maintenance....................................................................................................D-2
Calibration Specification ........................................................................................D-2/D-3
Major Component Locations.........................................................................................D-4

D-2 MAINTENANCE D-2
CALIBRATION SPECIFICATION
MAINTENANCE
WARNING
Safety Precautions ELECTRIC SHOCK can kill.
WARNING • Do not touch electrically live parts.

• When inching with the gun trigger,
ELECTRIC SHOCK can kill. electrode, wire drive motor and
drive mechanism are "hot" to work
• Do not touch electrically live parts and ground and could remain
such as output terminals or inter- energized several seconds after
nal wiring. the gun trigger is released.
• Welding power source must be
• When inching with gun trigger, electrode and connected to system ground per
drive mechanism are “hot” to work and ground the National Electrical Code or any
and could remain energized several seconds applicable local codes.
after the gun trigger is released. • Only qualified personnel should perform mainte-
nance work.
• 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 p.c.
guide tubes. board, potentiometer or motor is replaced or serviced.
Calibration matches the scale on the name plate to the
• Welding power source must be connected to sys- actual wire feed speed.
tem ground per the National Electrical Code or
any applicable local codes. To verify if calibration is necessary:
1. Turn off power to the LF-72.
• Only qualified personnel should perform mainte- 2. Assemble .045 drive rolls, inner guide and the
nance work. outer guide into the drive. Remove the gun from
------------------------------------------------------------------------ the wire feeder if assembled.
Observe all additional Safety Guidelines detailed 3. Load .045 wire into the drive. Cut the wire flush
throughout this manual. with the end of the gun bushing.
4. Set the WFS knob to 300 ipm.
ROUTINE MAINTENANCE 5. Using the COLD FEED switch, feed wire for 10
seconds.
6. Cut the wire flush with the end of the gun bushing.
• Clean and tighten all weld terminals.
Measure the length of the wire. If the wire mea-
• Inspect all weld cables, control cables, gun cables
sures 50 ± 2.5 inches then calibration is not
and shielding gas hoses. Repair or replace as nec-
required.
essary.
Tools required:
PERIODIC MAINTENANCE 5/16" nut driver
3/4" open end wrench
• Clean drive roll grooves. WFS meter or RPM meter
Shorting plug. The shorting plug shorts pins 1
• Blow out or vacuum the inside of the feeder. & 5 of connector J2 on the p.c. board. J2 is a
6 pin molex connector.
To calibrate the LF-72:

1. Turn off power to the LF-72.
2. Disconnect the electrode lead from the feedplate

and from the welding power source.
3. Remove the 5 screws securing the wraparound.

(The door is not shown for clarity. “See Figure
D.1”)
LF-72/74

D-3 MAINTENANCE D-3
FIGURE D.1
4. Open the idle arm. (For Codes above 11290 use 18)
5. Turn power on to the LF-72. 18. Replace P2 from the harness into connector J2.
6. Adjust the WFS knob to 300 ipm. Center the knob 19. Turn off power.
pointer with the name plate graphics.Activate the
gun trigger. 20. Secure the wraparound to the LF-72 with 5
screws.
7. Insert the shorting plug into connector J2 on the p.c.
board. The shorting plug shorts pins 1 & 5.
(See Figure D.2)
8. Remove the shorting plug. Set aside.

(For Codes below 11289 use 9 thru 17)

FIGURE D.2
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.

J2 CONNECTOR

D-4 MAINTENANCE D-4
1. Center Assembly
2. Wire Drive Assembly
3. Wire Reel Stand LF-72
FIGURE D.3 - MAJOR COMPONENT LOCATION
3
2
1
LF-72/74

Section AA-1 TABLE OF CONTENTS Section AA-1
- INSTALLATION SECTION -
Installation ............................................................................................................Section AA
Technical Specifications ............................................................................................AA-2

Safety Precautions .....................................................................................................AA-3
Location................................................................................................................AA-3
Mounting...............................................................................................................AA-3
Bench Mount ........................................................................................................AA-4
Swivel Mount ........................................................................................................AA-4
Boom Mount.........................................................................................................AA-4
Suspended ...........................................................................................................AA-4
Weld Cable Sizes..................................................................................................AA-5
Coaxial Weld Cables ............................................................................................AA-6
Weld Cable Connections ......................................................................................AA-6
Analog Control Cable Connections ...........................................................................AA-7
Analog Miller Control Cable Adapter .........................................................................AA-8
Welding Gun/Wire Feeder Trigger Connector ......................................................AA-9
High Frequency Protection...................................................................................AA-9
Remote Sense Lead Specifications .....................................................................AA-9
Wire Drive Systems....................................................................................................AA-9
Welding Guns, Torches and Accessories ................................................................AA-10
Wire Drive Configuration ..........................................................................................AA-11

Assembly of Drive Rolls and Wire Guides ...............................................................AA-12
Pressure Arm Adjustment ........................................................................................AA-13
Shielding Gas Connection .......................................................................................AA-14
Wire Reel Loading ..............................................................................................AA-15
Weld Wire Routing..............................................................................................AA-16
Installing Electrode Conduit Kits..............................................................................AA-17
Aluminum Wire Preparations ...................................................................................AA-18
Base Model, Bench Model and Extra Torque Bench Model ...................................AA-19
Common Equipment Set-Ups .................................................................................AA-20
High Volume Production ..........................................................................................AA-21
Portable Welding......................................................................................................AA-22
LF-72/74

AA-2 INSTALLATION AA-2
TECHNICAL SPECIFICATIONS: LF-74 Wire Feeder

SPEC.# TYPE WIRE FEED SPEED RANGE

Model Gearing GMAW FCAW
WFS Range Wire Sizes WFS Range Wire Sizes
.023 – 1/16" .030 - 5/64”

K2426-1 Normal Speed 100 – 800 ipm 100 – 800 ipm
(2.5-20.3 m/min.) (0.6 – 1.6mm) (2.5-20.3 m/min.) (0.8 - 2.0mm)
.023 – 1/16" .030 – 5/64"

K2426-2 Normal Speed 100 – 800 ipm 100 – 800 ipm
(2.5-20.3 m/min.) (0.6 – 1.6mm) (2.5-20.3 m/min.) (0.8 – 2.0mm)
K2426-3 Extra Torque 50 – 400 ipm .023 – 1/16" 50 – 400 ipm .030 – 3/32"
(1.3 – 10.4m/min) (0.6 – 1.6mm) (1.3 – 10.4m/min) (0.8 - 2.4mm)
CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS
SPEC.# TYPE INPUT POWER PHYSICAL SIZE• TEMPERATURE RATING

Input Voltage Dimensions
and Current Height Width Depth Weight Operating Storage
LF-74 11.1“ 10.2“ 12.9“ 46 Lbs.

K2426-1 ( 282 mm) (259 mm) (328 mm) (20.9 Kg.)
Base Model
Dimensions ∆
LF-74
K2426-2 24-42VAC 15.3“ 13.0“ 27.7“ 70.5 Lbs. 14°F to 104°F -40°F to 85°F
Bench 9 AMPS ( 389 mm) (330 mm) (704 mm) (32.0 Kg.) (-10°C to 40°C) (-40°C to 85°C)
Heavy 50/60 Hz
Duty
Dimensions ∆
LF-74
K2426-3 Bench 15.3“ 13.0“ 27.7“ 70.5 Lbs.
Heavy ( 389 mm) (330 mm) (704 mm) (32.0 Kg.)

Duty
Extra Torque
WELDING CAPACITY RATING

Amp Rating Duty Cycle
600 A 60%
500 A 100%
∆ Dimensions do not include wire reel.
ITEMS INCLUDED WITH EACH PRODUCT

Model Description Wire Wire Reel Stand Drive Roll Kit Control Cable
Feeder
K2426-1 Base Model -----------
K2426-2 Bench Model with

Heavy Duty Wire .035, .045 Combo 10Ft. (3m)

Stand LF-74 Heavy Duty, up to 60lb. (0.9, 1.2mm)
(27.k kg) Coils
K2426-3 Extra Torque
Model with Heavy
Duty Wire Stand
LF-72/74

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 AA.1) and for Bottom
lation or changing drive rolls and/or Mounting Holes (See Figure AA.2).
guides.
• When inching with the gun trigger, electrode FIGURE AA.1

and drive mechanism are "hot" to work and
ground and could remain energized several sec-
onds 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 main-

tenance work.
5/8-16 THREADS
(4 PLACES)
----------------------------------------------------------------------------------------
LOCATION
The LF-74 may be placed on a bench, mounted on top

of a welding power source or assembled to an appro-
priate boom.
Place the LF-74 in a clean and dry location.
Do not stack the LF-74.

FIGURE AA.2
1/4-20 THREADS
(4 PLACES)
5/16-18 THREADS
(4 PLACES) MOUNTING FEET
SECURED WITH
#10-24 SCREWS
(4 PLACES)
LF-72/74

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.
ing power source (CV-xxx and DC-xxx product family
only).
Bench Mount
SUSPENDED
SWIVEL MOUNT Only suspend the wire feeder by the handle/lift bail of
the portability kit.
The base model and heavy duty bench models may be
mounted onto a swivel when a top a welding power K2426-1 shown with K2328-1Standard Duty Wire Reel
source. Stand and K2331-1 Lift Bail
K1557-1Swivel Kit and Bench Model, with Heavy

Duty Wire Reel Stand.
WARNING
K2332-1 Swivel Kit and Base Model LF-74
Alternative methods for hanging the wire feeder
must not be used unless insulation is provided
between the wire feeder enclosure and the hanging
device.
------------------------------------------------------------------------
LF-72/74

SAFETY PRECAUTION

• Only qualified personnel should

input power to any other equipment

----------------------------------------------------------------------
WELD CABLE SIZES

Table A.1 has the copper cable sizes recommended for

different currents and duty cycles. Lengths stipulated
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 minimizing
voltage in the welding circuit.
TABLE AA.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
61 to 76 m
Amperes Cycle 0 to 15 m 15 to 31 m 31 to 48 m 48 to 61 m
200 60 2 2 2 1 1/0
200 100 2 2 2 1 1/0
225 20 4 or 5 3 2 1 1/0
225 40 & 30 3 3 2 1 1/0
250 30 3 3 2 1 1/0
250 40 2 2 1 1 1/0
250 60 1 1 1 1 1/0
250 100 1 1 1 1 1/0
300 60 1 1 1 1/0 2/0
325 100 2/0 2/0 2/0 2/0 3/0

350 60 1/0 1/0 2/0 2/0 3/0
400 60 2/0 2/0 2/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
500 60 2/0 2/0 3/0 3/0 4/0
** 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-72/74

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. The
feature low inductance, allowing fast changes in the small leads combine together to form the work lead,
weld current. Regular cables have a higher inductance one end attached to the power source and the other
which may distort the pulse wave shape. Inductance end to the work piece. (See Coaxial weld Cable below.)
becomes more severe as the weld cables become
longer.
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
Coaxial weld cables are recommended for all pulse to metal electrical contact. Poor work lead connections
welding, especially when the total weld cable length can result in poor welding performance.
(electrode cable + work cable) exceeds 50 feet (7.6m).
Coaxial Weld Cable Work
Electrode
Work
Power Source
Work Electrode Wire Feeder

Coaxial Weld Cable
Electrode
Work
LF-72/74

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 protection.

Connect the wire feeder only to power sources with
overcurrent protection of no more than 15 amps.

J A A J
I K B B K I
H N L C C L N H
G M M G
D D
F E E F
PIN FUNCTION LEAD#
A Reserved -------
B Reserved -------
C Welding Output Control 2
D Welding Output Control 4

E Remote Voltage Control 77

(“+” supply from feeder or remote)
F Remote Voltage Control 76
(control signal from feeder or remote)
G Remote Voltage Control 75
(“-” supply from feeder or remote)
H Reserved
I 42 VAC 41
J Reserved
K 42 VAC 42
L Reserved
M Reserved -------
N 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-72/74

ANALOG MILLER CONTROL CABLE

ADAPTER K2335-1
This Lincoln Electric wire feeder may be mounted to a
limited number of Miller Electric power sources. The
Miller power source must have the circular connector
pin definition shown in the table below for proper oper-
ation of the wire feeder. 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.
Operation of Lincoln wire feeders on Miller power

sources may result in lack of high wire feed speeds or
reduced pull force at high wire feed speeds.
Approximate maximum WFS for Lincoln wire feeders
operating with 24 VAC:
LF-72 720 ipm
LF-74 720 ipm

LF-74, extra torque 360 ipm
J A A J
I K B B K I
H N L C C L N H
G M D D M G
F E E F
MILLER POWER SOURCE LINCOLN WIRE FEEDER
Pin Function Pin Function

A 24 VAC to feeder I 42 VAC feeder

D Welding Output Control
B Welding Output Control C Welding Output Control
C +10VDC to feeder for remote control E Remote Voltage Control ("+" supply, from
power source)
D Remote control common G Remote Voltage Control ("-" supply, from
power source)
E 0-10VDC from feeder for remote control. F Remote Voltage Control (control signal from
feeder or remote.)
F Current feedback to feeder. J Reserved for future use.
Scaled 0-10V. 1 V = 100 amps.
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.
N N Electrode voltage to power source (67)

Miller is a registered trademark not owned or licensed by The Lincoln Electric Company.
LF-72/74

WELDING GUN/WIRE FEEDER TRIGGER

Drive Roll Kits, Cored Wires

CONNECTOR
Includes: 4 Knurled drive rolls and inner wire guide.
Wire Feeder
Amphenol KP1505-035C .030-.035" (0.8-0.9mm)
E KP1505-045C .040-.045" (1.0-1.2mm)
A D
Welding G un
KP1505-052C .052" (1.4mm)
KP1505-1/16C 1/16" (1.6mm)
B C Trigger Lead
Drive Roll Kits, Steel or Cored Wires
Includes: 4 Knurled drive rolls and inner wire guide.
Wire Feeder
KP1505-068 .068-.072" (1.8mm)
Pin Function
KP1505-5/64 5/64" (2.0mm)
A Gun Trigger
KP1505-3/32 3/32" (2.4mm)
B -
C Common
D -
E -
Drive Roll Kits, Aluminum Wire
Includes: 4 polished U groove drive rolls, outer wire
HIGH FREQUENCY PROTECTION guide and inner wire guide.
Locate the LF-74 away from radio controlled machin- KP1507-035A .035" (0.9 mm)
ery. The normal operation of the LF-74 may adversely KP1507-040A .040" (1.0mm)
affect the operation of RF controlled equipment, which KP1507-3/64A 3/64" (1.2mm)
may result in bodily injury or damage to the equipment. KP1507-1/16A 1/16" (1.6mm)
REMOTE SENSE LEAD SPECIFICATIONS

DRIVE ROLLS
Refer to the power source instruction manual for
instructions for connecting the wire feeder for STT
welding.
WIRE DRIVE SYSTEMS

Drive Roll Kits, Steel Wires

Includes: 4 Smooth V groove drive rolls and inner
wire guide.
INNER WIRE
KP1505-030S .023-.030 (0.6-0.8mm) GUIDE
KP1505-035S .035 (0.9mm)
KP1505-045S .045 (1.2mm)
KP1505-052S .052 (1.4mm)
KP1505-1/16S 1/16 (1.6mm)
LF-72/74

WELDING GUNS, TORCHES AND ACCES- 3. Fully insert the gun cable connector end into the
SORIES gun receiver bushing and gently tighten the thumb

screw as show in Figure AA.3 below.
4. Connect the gun trigger connector to the trigger
The LF-74 wire feeder comes with a K1500-2 gun
receptacle. Make sure that the key ways are
receiver bushing.
aligned and insert.
MAGNUM GUN AND CABLE ASSEMBLIES
The LF-74 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 AA.3
with a 15 ft. (4.6m) long Magnum 400 gun and cable.
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 AA.3
LF-72/74

WIRE DRIVE CONFIGURATION 7. Disconnect the shielding gas hose from the gun
(See Figure AA.5) bushing, if required.

Changing the Gun Receiver Bushing 8. Connect the shielding gas hose to the new gun
bushing, if required.
WARNING 9. Rotate the gun bushing until the thumb screw hole
ELECTRIC SHOCK can kill. aligns with the thumb screw hole in the feed plate.
• Turn the input power OFF at the Slide the gun receiver bushing into the wire drive
welding power source before instal- and verify the thumb screw holes are aligned.
lation or changing drive rolls and/or 10. Tighten the socket head cap screw.
guides. 11. Insert the welding gun into the gun bushing and
• Do not touch electrically live parts. tighten the thumb screw.
and could remain energized several seconds Gun Receiver For use With
after the gun trigger is released. Bushing
nance work. K1500-1 K466-1 Lincoln gun connectors;
------------------------------------------------------------------------ Innershield and Subarc guns)

Tools required:
• 1/4" hex key wrench K1500-2 K466-2, K466-10 Lincoln gun
Note: Some gun bushings do not require the use of connectors; Magnum 200/300/400
the thumb screw. guns and compatible with Tweco®
#2 - #4)
2. Remove the welding wire from the wire drive. K1500-3 K1637-7 Lincoln gun connectors;
3. Remove the thumb screw from the wire drive. Magnum 550 guns and compatible
4. Remove the welding gun from the wire drive. with Tweco® #5)
5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing. Important: K1500-4 K466-3 Lincoln gun connectors;
Do not attempt to completely remove the sock- compatible with Miller® guns.)
et head cap screw.
6. Remove the outer wire guide, and push the gun K1500-5 (Compatible with Oxo® guns.)
bushing out of the wire drive. Because of the pre-
cision fit, light tapping may be required to remove K489-7 ( Lincoln Fast-Mate guns.)
the gun bushing.

FIGURE AA.5
TIGHTEN
CAP
SCREW
LOOSEN
CAP
SCREW
THUMB
SCREW
CONNECTOR
BAR
SOCKET
HEAD CAP
SCREW
LF-72/74

ASSEMBLY OF DRIVE ROLLS AND WIRE To install drive rolls and wire guides:
(See Figure AA.7 and AA.7a)

GUIDES
WARNING 1. Turn off power at the welding power source.
2. Open pressure arms.

3. Assemble the inner wire guide.
• Turn the input power OFF at the
4. Slide the drive rolls onto the drive hubs.
lation or changing drive rolls and/or
(See figure AA.7)
guides.
5. Close the pressure arms.
6. Rotate 4 triangular rings to the locked position. (See
figure AA.7a)
7. Assemble the outer wire guide.
nance work.
------------------------------------------------------------------------
8. Adjust the pressure arms to the recommended set-
To remove drive rolls and wire guides:
ting.
(See Figure AA.6)
FIGURE AA.7
2. Remove the outer wire guide. DRIVE HUBS

PRESSURE ARMS
3. Rotate 4 triangular rings to the unlocked position. IN OPEN POSITION
INNER WIRE GUIDE

4. Open the pressure arms.
DRIVE ROLLS
5. Remove the drive rolls and inner wire guide.
FIGURE AA.6
2 PRESSURE ARMS
ROTATE DOWN
FIGURE AA.7a
4 TRIANGULAR RINGS SLIDE DRIVE ROLL

IN UNLOCKED POSITION ON DRIVE HUB
TRIANGULAR RING IN
UNLOCKED POSITION
TRIANGULAR RING IN
LOCKED POSITION
OUTER WIRE GUIDE

LF-72/74

PRESSURE ARM ADJUSTMENT

WARNING
• Turn the input power OFF at the welding power

source before installation or changing drive rolls
and/or guides.
nance work.
------------------------------------------------------------------------
The pressure arm controls the amount of force the drive

rolls exert on the wire. Proper adjustment of both pressure
arm gives the best welding performance. For best results,
set both pressure arms to the same value.
Set the pressure arm as follows (See Figure AA.8):

Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
FIGURE AA.8
CORED WIRES SOLID WIRES
OUTERSHIELD
12 ALUMINUM
METALSHIELD
INNERS HIELD
34
STEEL
56 STAINLE SS
LF-72/74

SHIELDING GAS CONNECTION

CYLINDER may explode if damaged. 6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
• Keep cylinder upright and chained to spring pressure is released.
support.
• Keep cylinder away from areas 7. Standing to one side, open the cylinder valve slowly
where it may be damaged. a fraction of a turn. When the cylinder pressure gage
• Never lift welder with cylinder attached. stops moving, open the valve fully.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live 8. The flow regulator is adjustable. Adjust it to the flow
electrical circuits. rate recommended for the procedure and process
------------------------------------------------------------------------ being used before making a weld.
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 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% CO2 cylinder, insert reg-
ulator adapter between regulator and cylinder valve.
If adapter is equipped with a plastic washer, be sure
it is seated for connection to the CO2 cylinder.
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.
LF-72/74

WIRE REEL LOADING 3. Re-install the retaining collar. Make sure that the
release bar snaps out and that the retaining collar

WARNING
FIGURE AA.10
• Keep hands, hair, clothing and tools away from
rotating equipment. Retaining
• Do not wear gloves when threading wire or Collar
changing wire spool.
• Only qualified personnel should install, use or
service this equipment.
-----------------------------------------------------------------------
Loading 10 to 15 lb. (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 Loading 30 lb. (13.6 kg) Readi-Reels
adapter for loading 2-1/2" (64mm) wide spools. (See (See Figure AA.11)
figure AA.9 and figure AA.10)

A K363-P Readi-Reel adapter is required for loading
1. Squeeze the release bar on the retaining collar and these spools on 2" (51mm) spindles.
2. Place the spindle adapter on the spindle, aligning 1. Squeeze the release bar on the retaining collar and
the spindle brake pin with the hole in the adapter. remove it from the spindle.
3. Place the spool on the spindle and align the adapter 2. Place the Readi-Reel adapter on the spindle, align-
brake tab with one of the holes in the back side of ing the spindle brake pin with one of the holes in the
the spool. An indicator mark on the end of the spin- adapter.
dle shows the orientation of the brake tab. Be cer- 3. Re-install the retaining collar. Make sure that the
tain the wire feeds off of the spool in the proper release bar snaps out and that the retaining collar
direction. fully engages the groove on the spindle.
4. Re-install the retaining collar. Make sure that the 4. Rotate the spindle and adapter until the retaining
release bar snaps out and that the retaining collar spring is at the 12 o’clock position.
FIGURE AA.9 5. Position the Readi-Reel so that electrode de-reels in
the proper direction.
Adapter 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.
Spindle Placement
The wire reel stand provides two mounting locations Removing a Readi-Reel
for the spindle. Each mounting location consists of a
tube in the center of the mast and locating slots. 1. To remove a Readi-Reel from the an adapter,
depress the retaining spring with a thumb while
Loading 16 to 44 lb. (7.3 – 20kg) Spools pulling the Readi-Reel cage from the adapter with
(See figure AA.8) both hands. Do not remove the adapter from the
spindle.
1. Squeeze the release bar on the retaining collar and

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 shows the orientation of the brake holding pin.
Be certain the wire feeds off of the spool in the prop-
er direction.
LF-72/74

FIGURE AA.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 minimum,
and also that the force required to pull the wire

from the reel into the wire drive unit is kept at a
minimum.
b) The electrode is “hot” when the gun trigger is

pressed and must be insulated from the boom and
structure.
c) 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-72/74

INSTALLING ELECTRODE 4. Loosen the set screw on the feed plate and remove
the incoming bushing.

CONDUIT KITS FIGURE AA.12a
SET
WARNING SCREW
CONDUIT
CONNECTOR

this equipment.
THUMB
• Do not touch electrically hot parts. SCREW
------------------------------------------------------------------------
Electrode conduit is used when feeding from wire
drums, boxes or large reels. For best feeding results,
use the shortest conduit length possible and avoid
sharp bends.
Tools required:
• 1/8" Hex key wrench 5. Insert the conduit connector into the feed plate and
• 5/16" Nut Driver secure with the set screw. Rotate the conduit con-
nector so the thumb screw does not interfere with
the idle arm or door.
To install Lincoln conduit:
1. Turn off power at the welding power source. 6. Mount the wire drive panel to the sheet metal hous-
FIGURE AA.12 ing with the six screws.
MOUNTING SCREWS * 7. Insert conduit through the sheet metal of the LF-74
SECURING WIRE DRIVE PANEL and into the conduit connector. Secure with the
thumb screw.
INCOMING
BUSHING
BALL
BUSHING
ASSEMBLY
O-RING
SET SCREW
MOUNTING SCREWS*
SECURING WIRE DRIVE PANEL
*REMOVE 6 MOUNTING SCREWS
2. Remove the o-ring holding the ball bushing assem-

bly to the back of the wire feeder. Remove the ball
bushing assembly.
3. Remove the six screws securing the wire drive panel
to the sheet metal housing.
LF-72/74

ALUMINUM WIRE PREPARATIONS FIGURE AA.13

WARNING
this equipment.
------------------------------------------------------------------------
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. 4. Place the ball bushing housing into the wire feeder
case and secure with the “O” ring.
To prevent scratching of the aluminum wire, remove

the ball bearings from the ball housing as follows.
Tools required: (See Figure AA.12b)

2. Remove the o-ring holding the ball bushing assem-

bly to the back of the wire feeder. Remove the ball
bushing assembly.
FIGURE AA.12b
"O" RING
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.
LF-72/74

BASE MODEL (K2426-1)

BENCH MODEL WITH HEAVY DUTY WIRE STAND (K2426-2)

EXTRA TORQUE BENCH MODEL WITH HEAVY DUTY WIRE STAND (K2426-3)
LF-72/74

COMMON EQUIPMENT SET-UPS

FIGURE AA.14 GENERAL FABRICATION
2B
2A
1C
4A
4B
5
Item K# Description
1A LF-74 Bench Model with Heavy Duty Wire Reel Stand

1B K2426-2 .035, .045 (0.9mm, 1.2mm) Drive Roll Kit
1C 10' (3m) Control Cable
1D See welding gun literature Magnum Gun
2A Deluxe Regulator for Mixed Shielding Gases

K586-1
2B Shielding Gas Hose
3 K1557-1 Swivel Kit
4A Ground Clamp
K1803-1
4B Weld Power Cables, Twist-Mate to Lug (2 included)
5 K2400-1 CV-305
LF-72/74

FIGURE AA.15 HIGH VOLUME

PRODUCTION
Item K# Description
1A LF-74, Base Model
1B K2426-1 .035, .045 (0.9, .1.2mm) Drive Roll Kit

1C 10' (3m) Control Cable.
- K1797-xx Control Cable Extension
1D See Welding Gun Literature Welding Gun
2 K2329-1 Remote Voltage Control Kit
3 K2330-1 Timer Kit
4 See Welding Arm Literature Welding Arm
5A K586-1 Deluxe Gas Regulator for Mixed Gases
5B Shielding Gas Hose
K884-xx Accu-Trak Drum Payoff Kit (Round)
6
K2175-xx Accu-Pak Box Payoff Kit (Square)
7 K1346-13 CV-400
8 K910-xx Ground Clamp
9 K1842-xx Weld Power Cable, Lug to Lug
10 K1546-1 Incoming Bushing, .035-1/16 (0.9 - 1.6 mm)
11 Conduit
LF-72/74

AA-22
Control Cable Extension. Add cables to extend up to 110' (30m)

LF-74 Extra Torque Bench Model with Heavy Duty Wire Reel Stand
Plastic Wire Cover for 50-60lb. Wire Packages

10
Weld Power Cables, Twist Mate to Lug

5
.035, .045 (0.9, 1.2mm)Drive roll Kit

35
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Insulated Lift Bail Kit
Shielding Gas Hose

R
POWE
Ground Clamp
OFF
ON
Description
TE
REMO
ING
WARN
9
3C, 4
FIGURE AA.16 PORTABLE WELDING
8
INSTALLATION
7A
5C
LF-72/74
6 5A
3D
See Power Source or Engine

See Welding Gun Literature
3A
Drive Literature

K1797-xx
K2329-1
K2426-3
K2331-1
K1634-2
K1803-1
K586-1
KPxxx
K163
K#
2
Item
3C
3D
5C
3A
5A
7A
10
1
2
6
7
8
9
AA-22 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Section BB-1 TABLE OF CONTENTS Section BB-1
- OPERATION SECTION -
Operation..............................................................................................................Section BB
Safety Precautions .....................................................................................................BB-2

Graphic Symbols .......................................................................................................BB-2
Common Welding Abbreviations ...............................................................................BB-2
Product Description ...................................................................................................BB-3
Recommended Processes and Required Equipment ...............................................BB-3
Front Panel Controls and Connections .....................................................................BB-4
1. Wire Feed Speed Knob ....................................................................................BB-5
2. Remote Voltage Control Kit (Optional) .............................................................BB-5

3. Burnback and Postflow Timer Kit (Optional)....................................................BB-5
4. Thermal LED, Motor Overload .........................................................................BB-5
5. Cold Feed/Gas Purge Switch...........................................................................BB-5
6. 2 Step - Trigger Interlock Switch .....................................................................BB-6
7. Gun Receiver Bushing......................................................................................BB-6
8. Trigger Connector 5-Pin Amphenol..................................................................BB-6
POWER FEED 10M SINGLE/DUAL

BB-2 OPERATION BB-2
SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

Read this entire section of operating instructions
before operating the machine.
COLD FEED
WARNING
POSITIVE OUTPUT
• Unless using cold feed feature, when
feeding with the gun trigger, the elec- NEGATIVE OUTPUT
trode and drive mechanism are
always electrically energized and
could remain energized several sec- PROTECTIVE
onds after welding ceases. GROUND
• Do not touch electrically live parts or electrodes
with your skin or wet clothing.
• Insulate yourself from the work and ground. WARNING OR

• Always wear dry insulating gloves. CAUTION
-------------------------------------------------------------
ONLY QUALIFIED PERSONS SHOULD INSTALL,
USE OR SERVICE THIS EQUIPMENT. READ AND
DANGEROUS
FOLLOW THE MANUFACTURER’S INSTRUCTIONS, VOLTAGE
EMPLOYER’S SAFETY PRACTICES AND MATERI-
AL SAFETY DATA SHEETS (MSDS) FOR CONSUM- SHOCK
ABLES.
HAZARD
-----------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF & WELDING
OTHERS.
FUMES
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
EXPLOSION
• Use ventilation or exhaust at the arc,

or both, to keep fumes and gases
from your breathing zone and gener-
al area. GAS INPUT
WORK
WELDING SPARKS can cause fire or
CONNECTION
explosion.
• Do not weld near flammable material.
COMMON WELDING ABBREVIATIONS
• Do not weld on containers which have
held flammable material. WFS
ARC RAYS can burn. • Wire Feed Speed
• Wear eye, ear, and body protection. CV

• Constant Voltage
----------------------------------------------------------- GMAW (MIG)

• Gas Metal Arc Welding
Observe additional guidelines detailed in the begin-
ning of this manual.
FCAW (Innershield or Outershield)
• Flux Core Arc Welding
LF-72/74

BB-3 OPERATION BB-3
PRODUCT DESCRIPTION General Functional Description

The LF-74 fulfills the need for an economical wire feed-

General Physical Description er with a high performance wire drive. Functional fea-
The LF-74 is optimized for GMAW and FCAW welding. tures included are those that offer the most value – a
The powerful 4 roll MaxTrac™ drive, heavy duty enclo- WFS knob with a calibrated printed scale, cold-feed/
sure and wire reel stand combine to make an easy to gas purge switch, trigger interlock switch and tachome-
install, easy to use wire feeder for everyday welding. ter motor control.
Powering the wire drive is a high performance motor
gearbox. A heavy duty hinged door opens easily, which RECOMMENDED PROCESSES
provides an ample amount of room for assembling pre- • GMAW
cision drive components and the welding gun. • FCAW
MaxTrac™ technology delivers great feeding because: PROCESS LIMITATIONS
• Patent pending drive rolls improve traction. • The LF-74 is not recommended for GMAW-Pulse
• The precision machined, rigid aluminum alloy frame Synergic, GTAW, GTAW-Pulse, CAG, SMAW
results in maximum drive roll clamping pressure. • The LF-74 is not compatible with push-pull equip-
• Drive hubs with steel inner cores have 3 ball bear- ment.
ings inside each hub. • For the heavy duty bench models K2426-2 and
• The drive hubs are supported by large, heat treated K2426-3, the maximum spool size = 60 lb. (27.2 kg).
and ground shafts for maximum rigidity and accurate
drive roll alignment. REQUIRED EQUIPMENT
• Patent pending dual spring pressure arms have sen-
Lincoln’s LF-74 is designed for use with the CV and DC
sitivity for feeding soft wires without crushing them,
family of power sources. These include:
and have plenty of compression force for feeding
• CV-250 • DC-400
solid or stiff wires.
• CV-300 • DC-600
• CV-305 • DC-655
Easy to configure, easy to service parts give
• CV-400 • Invertec V350
MaxTrac™ drives the edge in productivity.
• CV-655
• Patented split wire guides fully support the wire and
virtually eliminate birdnesting.
OTHER COMPATIBLE POWER SOURCES
• No tools required to change the drive rolls and wire
• Ranger 250
guides.
• Ranger 305
• Changeable gun bushings easily accept guns from
• Commander 300
many manufacturers.
• Vantage 300
• Brass-to-brass connections between the electrode
• Vantage 500
connection and the gun minimize voltage drop varia-
• Air Vantage 500
tions, resulting in consistent arc performance all day,
every day.
EQUIPMENT LIMITATIONS
• Maximum GMAW gun length = 25’ (7.6m)
Three models of the LF-74 are available to satisfy
• Maximum FCAW gun length = 15’ (4.6m)
many customer set-ups:
• Maximum conduit length = 30' (9.1m)
• The base model is enhanced for GMAW welding with
• Maximum total control cable length = 100ft (31m)
consumables from bulk packages or when a boom
• The LF-74 operates on 24-42VAC and not 115 VAC
mounting is required.
• The K1733-1 and K1733-3 wire straighteners are not
• The bench model with heavy duty wire reel stand tar-
compatible with the LF-74
gets operators performing GMAW or FCAW welding
• Gun bushings are required for welding guns that do
using consumables on spools.
not have a Magnum (Tweco #2-#4 compatible) back
• The high torque model features high ratio gearing for
end.
feeding larger diameter FCAW or GMAW wires.
• The LF-74 does not attach to K303 or K377 wire reel
stands.
All models use a high performance motor-gear box

with an integrated tachometer.
LF-72/74

BB-4 OPERATION BB-4
FRONT PANEL CONTROLS AND CONNECTIONS

FIGURE BB.1 CASE FRONT CONTROLS
3
8
ITEM DESCRIPTION
1 Wire Feed Speed Knob.
2 Location for Optional Remote Voltage Control (See Accessory Section For Kit Number).
3 Location for Optional Burnback and Postflow Timer Kit (See Accessory Section For Kit Number).
4 Thermal LED, Motor Overload.
5 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.
6 2 step - Trigger Interlock switch.
7 Gun Receiver Bushing.

8 Trigger Connector 5-pin amphenol for connecting the MIG gun trigger. See Installation Section
for detail.
LF-72/74

BB-5 OPERATION BB-5
1. WIRE FEED SPEED KNOB To set the burnback time, adjust the knob to approxi-
The large, calibrated wire feed speed knob makes for mately 0.03 seconds and then decrease or increase
easy and accurate adjustment of the wire feed speed. the time as desired.
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.
K2426-1 and K2426-2 models:

These wire feeders are factory configured for normal
speed operation.
The normal wire feed speed range is 100 to 800 in/min

(2.5 - 20.3 m/min).
Postflow Timer
K2426-3 model: The postflow timer range is OFF to 10 seconds.
The wire feed speed range on the extra torque model Postflow is the time from when the power source out-
is 50 to 400 in/min (1.3 – 10.2 m/min) put turns OFF until the postflow timer expires. Use
postflow to protect the weld while the weld cools.
2. REMOTE VOLTAGE CONTROL KIT

The optional remote voltage control kit adjusts the arc
4. THERMAL LED, MOTOR OVERLOAD
voltage from the minimum to the maximum voltage of The thermal light illuminates when the wire drive
the welding power source. Rotate the knob counter- motor draws too much current. If the thermal light illu-
clockwise to reduce the arc voltage and rotate the minates, the wire drive will automatically shutdown for
knob clockwise to raise the arc voltage. 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.
5. COLD FEED/GAS PURGE SWITCH

Cold Feed and Gas Purge are combined into a single
3. BURNBACK AND POSTFLOW TIMER KIT spring centered toggle switch.
The optional Burnback and Postflow Timer Kit gives
control over the shielding gas at the end of the weld To activate Cold Feeding, hold the switch
and prepares the end of the wire for the next arc start. in the UP position. The wire drive will feed
Additional shielding gas protection is often required electrode but neither the power source
when welding aluminum, stainless steel or exotic nor the gas solenoid will be energized.
alloys. Adjust the speed of cold feeding by rotat-
ing the WFS knob. Cold feeding, or "cold
When stitch welding, set the postflow time to maxi- inching" the electrode is useful for thread-
mum for best results. ing the electrode through the gun.
Burnback Timer Hold the toggle switch in the DOWN posi-

The burnback timer range is OFF to 0.25 seconds. tion to activate Gas Purge and let the shielding gas
The burnback timer controls the additional amount of flow. The gas solenoid valve will energize but neither
time the power source output remains ON after the the power source output nor the drive motor will be
wire drive has stopped feeding wire. Burnback adjust- turned on. The Gas Purge switch is useful for setting
ment prevents the wire from sticking to the weld at the the proper flow rate of shielding gas. Flow meters
end of a weld and helps to condition the wire for the should always be adjusted while the shielding gas is
next weld. flowing.
LF-72/74

BB-6 OPERATION BB-6
6. 2 STEP - TRIGGER INTERLOCK 7. GUN RECEIVER BUSHING (K1500-2)

SWITCH (K1500-2 bushing is standard on all LF-74's)

The 2 Step - Trigger Interlock switch This Gun Receiver Bushing is used with Lincoln gun
changes the function of the gun trigger. 2 connectors, also with Magnum 200/300/400 guns and
Step trigger operation turns welding on compatible with Tweco® #2-#4).
and off in direct response to the trigger.
Trigger Interlock operation allows welding 8. TRIGGER CONNECTOR 5-PIN AMPHENOL
to continue when the trigger is released This is used for connecting the MIG gun trigger. See
for comfort on long welds. Installation Section for detail.
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.
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 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.
------------------------------------------------------------------------
LF-72/74

Section CC-1 TABLE OF CONTENTS Section CC-1
- ACCESSORIES SECTION -
Accessories .........................................................................................................Section CC
General Options / Accessories.....................................................................CC-2/CC-5


CC-2 ACCESSORIES CC-2
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. up to 44 lbs (20 kg) spools,
Spindle and mounting hard-
ware.
K2331-1 Lift Bail Kit. Includes: Insulated lift bail

for use with K2328-1 and hardware.
K2332-1 Swivel Kit. Includes: Swivel adapter and

(for use with K2328-1 Standard mounting hardware for attach-
Duty Bench Models) ing to a power source lift bale.
Includes: Coaxial weld cable

of length "xx". Ends of the
K1796-xx Co-Axial Power Cable. 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
K1803-1 Work and Feeder Cables Ground Clamp, and Twist-

Package. 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".
Includes: Twist-Mate to Twist-

Mate, 1/0 Cable for 25' (7.6m)
K1841-xx Weld Power Cable, cables.
Twist-Mate to Twist-Mate. 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
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-72/74

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.
Includes: One transformer kit

K1520-1 42 Volt Transformer Kit. for operating a 42 VAC wire
feeder on a power source
supplying only 115 VAC.
K1798 Adapter Cable for Control Cable to Includes:

Terminal Strip Power Sources.

Ground Clamp.

Ground Clamp.

K1500-1 with K466-1 Lincoln gun connec- ing, set screw and hex key
tors; Innershield and Subarc wrench.
guns.)
Gun Receiver Bushing (for guns with
K1500-2 K466-2, K466-10 Lincoln gun connec- ing with hose nipple, set
(standard on all tors; Magnum 200/300/400 guns and screw and hex key wrench.
LF-74's) compatible with Tweco® #2-#4.)

K1500-3 with K613-7 Lincoln gun connec- ing with hose nipple, set
tors; Magnum 550 guns and com- screw and hex key wrench.
patible with Tweco® #5.)
Gun Receiver Bushing (for gun Includes: Gun receiver bush-

with K466-3 Lincoln gun connec-
K1500-4 ing with hose nipple, set
tors; compatible with Miller®
guns.) screw and hex key wrench.

K1500-5 Gun Receiver Bushing (compatible ing with hose nipple, 4 guide
with Oxo® guns.) tubes, set screw and hex key
wrench.
LF-72/74

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. adapter and hex key wrench.

Conduit .025- 1/16" (0.6 - 1.6mm) and hex key wrench.
wire.

Conduit 1/16-1/8" (1.6 - 3.2 mm ) and hex key wrench.

wire.
K435 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. (Electrode not included.)
K468 Spindle Adapter, for mounting 8in Includes: Spindle Adapter.

(203mm) diameter spools on 2 in
(51 mm) spindles.
K468-1 Spindle Adapter, for mounting 2.5 Includes: Spindle Adapter.

in (64mm) diameter spools on 2 in
(51 mm) spindles.
K363P Readi-Reel Adapter, for mounting Includes: Readi-Reel spool

23-30 lb. (10.4 - 13.6 kg) reels to 2 adapter. (Spool of electrode

in (51 mm) spindles. not included.)
K438 Readi-Reel Adapter, for mounting Includes: Readi-Reel spool

50-60 lb. (22.7 - 27.2 kg) reels to adapter. (Spool of electrode
2 in (51 mm) spindles. For use not included.)
with Heavy Duty Bench models.
K1504-1 Coil Adapter, for mounting 50-60

lb. (22.7 - 27.2 kg) coils to 2 in (51 Includes: 50-60 lb. (22.7 -
mm) spindles. 27.2 kg) coil adapter.
For use with heavy Duty Bench
LF-72/74

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" - 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 lb.

(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 lb. 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, brackets and
mounting hardware.
Insulated Lift Bail Includes: Insulated Lift Bail

K1555-1 (for use with Heavy Duty Bench and mounting hardware.
Models)
LF-72/74

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CC-6

LF-72/74
NOTES
CC-6
Section DD-1 TABLE OF CONTENTS Section DD-1
- MAINTENANCE SECTION -
Maintenance ........................................................................................................Section DD
Safety Precautions ......................................................................................................DD-2

Routine Maintenance ..................................................................................................DD-2
Periodic Maintenance .................................................................................................DD-2
Calibration Specification .............................................................................................DD-2
Major Component Locations ......................................................................................DD-4

DD-2 MAINTENANCE DD-2
MAINTENANCE Calibration of the LF-74 may be required when the p.c.

board, potentiometer or motor is replaced or serviced.

Safety Precautions 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. 1. Assemble a .045 (1.2 mm) drive roll kit to the feed-
er.
• Do not touch electrically live parts 2. Load .045 (1.2 mm) steel wire into the feeder.
such as output terminals or inter- 3. Trim the wire to the end of the contact tip of the gun.
nal wiring. 4. Adjust the WFS knob per the Table D.1.
TABLE D.1
• When inching with gun trigger, electrode and
drive mechanism are “hot” to work and ground
and could remain energized several seconds MODEL WFS knob setting
after the gun trigger is released. K2426-1, K2426-1 400
• Turn OFF input power at welding power source K2426-3 200
before installation or changing drive roll and/or
5. Activate and hold the COLD FEED switch for 10

guide tubes. seconds.

• Welding power source must be connected to sys- 6. Measure the length of wire extending from the con-
tem ground per the National Electrical Code or tact tip. The wire length shown in Table D.2.
any applicable local codes. TABLE D.2
nance work. MODEL WIRE LENGTH
------------------------------------------------------------------------ K2426-1, K2426-1 50 inches ± 5 inches (1270 mm ± 127mm)
K2426-3 25 inches ± 2.5 inches (635 mm ± 64 mm)
Observe all additional Safety Guidelines detailed
throughout this manual. To calibrate the wire feed speed,
ROUTINE MAINTENANCE Tools required:
• Clean and tighten all weld terminals. • 5/16" nut driver
• Inspect all weld cables, control cables, gun cables • 3/4" open end wrench
and shielding gas hoses. Repair or replace as nec- • WFS meter or RPM meter
essary. • Shorting plug. The shorting plug shorts pins 1 and 5
of connector J2 on the p.c. board. J2 is a 6 pin
molex.
PERIODIC MAINTENANCE
• Clean drive roll grooves. 1. Turn off power to the LF-74 and welding power
• Blow out or vacuum the inside of the feeder. source.
2. Disconnect the electrode lead from the feed plate
CALIBRATION SPECIFICATION and from the welding power source.
3. Remove the wraparound from the LF-74, See
WARNING Figure D.1.
4. Turn on power to the LF-74 and welding power
ELECTRIC SHOCK can kill. source.
• Do not touch electrically live parts. 5. Adjust the WFS knob per the Table D.1.
• When inching with the gun trigger, 6. Insert the shorting plug into the control p.c. board J2.
electrode, wire drive motor and (shorts pins 1 and 5.) See Figure D.2.
drive mechanism are "hot" to 7. Wait a minimum of 1 second.
work and ground and could 8. Remove the shorting plug.
remain energized several seconds 9. Connect J2 of the harness to p.c. board.
after the gun trigger is released. 10. Turn off power to the LF-74 and welding power
• Welding power source must be source.

connected to system ground per 11. Assemble the wraparound.

the National Electrical Code or 12. Connect the electrode lead.
any applicable local codes.
nance work.
------------------------------------------------------------------------
LF-72/74

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DD-3

LF-72/74
FIGURE DD.1
FIGURE DD.2
MAINTENANCE
J2 CONNECTOR
DD-3
DD-4 MAINTENANCE DD-4
1. Center Assembly
2. Wire Drive Assembly

FIGURE DD.3 - MAJOR COMPONENT LOCATION
3
2
1
LF-72/74

Section E-1 TABLE OF CONTENTS Section E-1
- THEORY OF OPERATION SECTION -

Theory of Operation ...............................................................................................Section E
General Description ......................................................................................................E-2

Input Receptacle, Control Board and Operator Controls.............................................E-2
Drive Motor, Tach Feedback and Gas Solenoid...........................................................E-3
FIGURE E.1 – LF-72/74 BLOCK LOGIC DIAGRAM
GAS
SOLENOID
3.75 AMP
OVERLOAD
PROTECTION
WIRE
DRIVE
MOTOR
OPTIONAL OPTIONAL
WIRE DRIVE TACK
BURNBACK REMOTE
RECEPTACLE
TIMER VOLTAGE
CONTROL To Gun Trigger
14 PIN
INPUT CABLE
CONTROL BOARD
RECEPTACLE
COLD FEED
GAS PURGE
24/42 VAC
TRIGGER
WIRE FEED
INTERLOCK
SPEED POT.
2-STEP

E-2 THEORY OF OPERATION E-2
FIGURE E.2
GENERAL DESCRIPTION & INPUT RECEPTACLE, CONTROL BOARD AND OPERATOR CONTROLS
GAS
SOLENOID
3.75 AMP
OVERLOAD
PROTECTION
WIRE
DRIVE
MOTOR
OPTIONAL OPTIONAL
WIRE DRIVE TACK
BURNBACK REMOTE
RECEPTACLE
TIMER VOLTAGE
14 PIN
INPUT CABLE
CONTROL BOARD
RECEPTACLE
COLD FEED
GAS PURGE
24/42 VAC
TRIGGER
WIRE FEED
INTERLOCK
SPEED POT.
2-STEP
GENERAL DESCRIPTION INPUT RECEPTACLE, CONTROL

BOARD AND OPERATOR CON-
The LF72 and LF74 are single head, 24vac or 42vac TROLS
input, 2 roll (LF72) or 4 roll (LF74) wire feeders. They The 24 or 42-volt input is applied to the LF72 or LF74
have a single calibrated control for wire feed speed through the 14 pin amphenol type connector. The
WFS and an optional K2339-1 remote voltage control remote trigger leads are accessed through 14 pin
kit to be used in conjunction with a Lincoln constant receptacle. The input voltage is rectified by a full wave
voltage (CV) direct current DC power source. bridge and is sent to a switching power supply in the
The LF72 and LF74 offer the user 3 individual features control board where it is filtered. This filtered DC volt-
Cold feed, trigger interlock 2 step trigger control and age is applied to a switching power supply. The
gas purge. Presettable burnback and postflow timers switching power supply manufactures +15vdc and
are also available with an optional K2330-1 timer kit. +5vdc regulated supplies for the control board circuit-
ry.
The motor is equipped with a 3.75amp current over-
draw protection circuit, which is indicated by a THER- The control board receives commands from the user
MAL LED located on the case front. operated controls for the wire feed speed WFS pot,
the optional timer kit and the optional voltage remote
control kit. It compares this feedback information with
the user command signals and generates appropriate
signals to control wire feed speed, arc voltage and gas
flow.
The control board is also responsible for the operation

of the trigger interlock, 2-step, cold feed and the gas
purge features of the LF72 and the LF74.

E-3 THEORY OF OPERATION E-3
FIGURE E.3 – DRIVE MOTOR, TACH FEEDBACK AND GAS SOLENOID

GAS
SOLENOID
3.75 AMP
OVERLOAD
PROTECTION
WIRE
DRIVE
MOTOR
OPTIONAL OPTIONAL
WIRE DRIVE TACK
BURNBACK REMOTE
RECEPTACLE
TIMER VOLTAGE
14 PIN
INPUT CABLE
CONTROL BOARD
RECEPTACLE
COLD FEED
GAS PURGE
24/42 VAC
TRIGGER
WIRE FEED
INTERLOCK
SPEED POT.
2-STEP
DRIVE MOTOR, TACH FEEDBACK

AND GAS SOLENOID
The leads to the drive motor, gas solenoid and the

tach (hall effect device LF-74 and LF-72 above codes
11290) are brought into the control box via the 14 pin
receptacle. This 14 pin receptacle also houses the
gun trigger leads and the voltage sense leads. When
the gun trigger is activated the control board energizes
the gas solenoid, the wire drive motor and the welding
power source. The control board receives a tach feed-
back signal and adjusts the motor armature voltage to
match the preset wire feed speed.
The control board also monitors the drive motor

amperage and will shut down the wire drive for 30 to
60 seconds to allow the motor to cool if the amperage
exceeds 3.75 amps for an extended time.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
LF-72/74

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-4

LF-72/74
NOTES
E-4
Section F-1 TABLE OF CONTENTS Section F-1
- TROUBLESHOOTING & REPAIR SECTION -

Troubleshooting & Repair Section ........................................................................Section F
How to Use Troubleshooting Guide..............................................................................F-2

PC Board Troubleshooting Procedures and Replacement...........................................F-3
Troubleshooting Guide ..................................................................................................F-4
Test Procedures
Drive Motor and Tach Feedback Test..............................................................F-7/F-8
Gas Solenoid Test ..........................................................................................F-9/F-10
Diode Bridge Test ........................................................................................F-11/F-12
Wire Speed Potentiometer Test ...................................................................F-13/F-14

Replacement Procedures
PC Board Removal and Replacement.........................................................F-15/F-16
Wire Drive Motor and Gear Box Removal and Replacement......................F-17/F-20
Retest After Repair ...............................................................................................F-21

F-2 TROUBLESHOOTING & REPAIR F-2
HOW TO USE TROUBLESHOOTING GUIDE

CAUTION
Service and repair should be performed by only 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 Step 3. PERFORM COMPONENT TESTS. The
you locate and repair possible machine last column, labeled “Recommended Course of
malfunctions. Simply follow the three-step Action” lists the most likely components that may
procedure listed below. have failed in your machine. It also specifies the
appropriate test procedure to verify that the
subject component is either good or bad. If there
Step 1. LOCATE PROBLEM (SYMPTOM). Look are a number of possible components, check the
under the column labeled “PROBLEM components in the order listed to eliminate one
(SYMPTOMS)”. This column describes possible possibility at a time until you locate the cause of
symptoms that the machine may exhibit. Find your problem.
the listing that best describes the symptom that
the machine is exhibiting. Symptoms are
grouped into three main categories: Feeding All of the referenced test procedures referred to in
Problems and Welding Problems. the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
Step 2. PERFORM EXTERNAL TESTS. The locate each specific Test Procedure. All of the
second column, labeled “POSSIBLE AREAS OF referred to test points, components, terminal
MISADJUSTMENT(S)”, lists the obvious external strips, etc., can be found on the referenced
possibilities that may contribute to the machine electrical wiring diagrams and schematics. Refer
symptom. Perform these tests/checks in the to the Electrical Diagrams Section Table of
order listed. In general, these tests can be Contents to locate the appropriate diagram.
conducted without removing the case
wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
LF-72/74

PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the PC board from the static-shielding bag

WARNING and place it directly into the equipment. Don’t set the
ELECTRIC SHOCK PC board on or near paper, plastic or cloth which
can kill. could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
• Have an electrician install and ing bag.
service this equipment. Turn the
input power OFF at the fuse box - If the PC board uses protective shorting jumpers,
before working on equipment. Do don’t remove them until installation is complete.
not touch electrically hot parts.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
CAUTION er failure analysis.
Sometimes machine failures appear to be due to PC 4. Test the machine to determine if the failure
board failures. These problems can sometimes be

symptom has been corrected by the

traced to poor electrical connections. To avoid prob- replacement PC board.
lems when troubleshooting and replacing PC boards,
please use the following procedure: NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component NOTE: Allow the machine to heat up so that all
causing the failure symptom. electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly 5. Remove the replacement PC board and
connected. substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
a. If the original problem does not reappear by
board using standard practices to avoid static
substituting the original board, then the PC
electrical damage and electrical shock. Read
board was not the problem. Continue to look
the warning inside the static resistant bag and
for bad connections in the control wiring
perform the following procedures:
harness, junction blocks, and terminal strips.

PC board can be damaged by static electricity. b. If the original problem is recreated by the
- Remove your body’s static substitution of the original board, then the PC
charge before opening the static- board was the problem. Reinstall the
shielding bag. Wear an anti-static replacement PC board and test the machine.
wrist strap. For safety, use a 1 6. Always indicate that this procedure was
Meg ohm resistive cord connected followed when warranty reports are to be
ATTENTION to a grounded part of the submitted.
Static-Sensitive equipment frame. NOTE: Following this procedure and writing on the
Devices - If you don’t have a wrist strap, warranty report, “INSTALLED AND SWITCHED PC
Handle only at touch an un-painted, grounded, BOARDS TO VERIFY PROBLEM,” will help avoid
Static-Safe part of the equipment frame. Keep denial of legitimate PC board warranty claims.
Workstations touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.

- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.
LF-72/74

LF-72/74
Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FUNCTION PROBLEMS
The wire drive does not feed wire 1. Power source not on 1. Verify the power source is on
and the drive rolls do not spin
2. Possible tripped breaker Verify power is being applied to
the wire feeder
3. Faulty gun trigger
2. Verify the circuit breaker of the
4. Possible faulty control cable
wire feeder or the power source
has not tripped
3. Check to see if the gun trigger is
working properly
4. Check for cable continuity, and

for broken or bent pins.
The wire feeds erratically, or the 1. Wrong drive rolls installed. 1. Verify the correct drive rolls and
motor LED lights. inner wire guides are installed in
2. Possible problem with gun the wire drive
3. Pressure arm or brake tension to 2. Check for sharp bends in gun

tight. liner
4. Examine the contact tip for wear Check gun liner. The welding elec-
or proper size trode should slide easily through
the gun. Verify proper gun liner is
installed
3. Adjust brake tension. Adjust

pressure arm see FIGURE A.6
4. Replace if necessary
5. If using wire conduit, verify that

the wire slides easily through the
conduit.
6. Perform the WIRE DRIVE

MOTOR TEST. Perform TACH
FEEDBACK TEST.
The wire continues to feed when 1. Trigger interlock switch in wrong 1. Check if the 2 step/ trigger inter-
the gun trigger is released. position. lock switch is in the TRIGGER
INTERLOCK position.
2. Gun trigger shorted or stuck
2. Verify operation of the gun trig-
ger. Check for shorted trigger
leads.
CAUTION
tact the Lincoln Electric Service Department at 1-888-935-3877 for electrical troubleshooting assistance before
you proceed.

LF-72/74

FUNCTION PROBLEMS (Continued)
No shielding gas. 1. No gas supply, or gas supply 1. Verify cylinder is not empty and
interrupted. is turned on.
2. Solenoid not functioning. Check the hose for cuts or kinks.
Make sure it is not crushed.
Verify the hose is connected to the
gun bushing or welding gun.
2. Perform the GAS SOLENOID
TEST.
Variable or hunting arc. 1. Bad contact tip 1. Check for proper size contact
2. Possible loose connection in tip. Make sure tip is not worn,
current carrying cables. and is free of spatter.

3. Set up not correct. 2. Clean and tighten all electrode
4. Problem with shielding gas. and work connections. Verify
the gun bushing is tightly
mounted to the wire drive.
Verify the gun is tightly mounted
to the gun bushing.
3. Verify the proper polarity is
being used for the weld proce-
dure. Make sure the proper
electrode stick-out is being
maintained.
4. Check the gas flow rate and
mixture.
5. Control board may be faulty.
When the trigger is pulled, the 1. Possible bad gun or faulty con- 1. Check all electrode and work
drive rolls spin but no arc voltage nections in the heavy current connections. Verify the the gun
carrying leads. bushing is tight to the wire
drive. Verify gun is tightly
2. Possible faulty control cable.
mounted to the bushing.
3. Possible defective power
2. Check the control cable and
source.
connectors for continuity, cuts,
or broken pins.
3. Verify the power source is oper-
ating properly.
The arc burns back to the tip. 1. If timer kit is installed, reduce
the amount of burnback time.
2. If the timer kit is installed,
The gas continues to flow for a
reduce the amount of post flow
long time after the weld.

time.
CAUTION
you proceed.

LF-72/74

FUNCTION PROBLEMS (Continued)
The motor (L12081) failed when a When testing the wire drives for This can be done by loading a
load (6 N m) was applied to the feeding problems (“inconsistent spool of wire, setting the spindle
wire drive. feeding”, “grinding noises from the brake to maximum and hen feed-
gearbox”, “jumping drive rolls”) the ing wire.
wire drive should be tested under
load.
CAUTION
you proceed.
LF-72/74

DRIVE MOTOR AND TACH FEEDBACK TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained
personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician or machine operator and will invalidate your factory warranty. For
your safety and to avoid electrical shock, please observe all safety notes and pre-
cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to per-
form the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the wire drive motor is receiving the correct voltage and
is capable of running properly. It will also determine if the tach sensor is receiving the
correct input from the control board, and is sending back the correct signal.
MATERIALS NEEDED
5/16 in. nut driver
32 VDC @ 1 amp variable power source
Volt-Ohm Meter
LF-72/74

MOTOR AND TACH FEEDBACK TEST (continued)

TEST PROCEDURE 6. Check for between 1 and 2 ohms of resistance

between the above mentioned leads. Also make
1. Remove power from the LF72/LF74 wire drive unit. sure there is at least 500k ohms of resistance
between both leads and the motor shell.
2. Using a 5/16 nut driver remove the 5 screws hold-
ing the case. 7. With the trigger activated and the motor running
check for 5VDC input on the black and red tach
3. Locate the two motor leads and the tach leads See leads. Check for .7 VDC to .85 VDC on the black
Figure F.1. and blue return leads.
4. Apply the correct input voltage (42VAC) to the unit. 8. For further testing on the drive motor you can use
an isolated power source and apply between 1 and
5. With the trigger activated and the motor running 31VDC to the leads.
check for 1VDC min. (210HZ) to 31VDC
(1.75KHZ)max. between the black and white motor 9. If the armature voltage is not present (step 5) and
leads (pins 7 and 8). the motor operates normally when an isolated
power source is applied (step 8) Control board may
be faulty.
FIGURE F.1 – TACH LEAD LOCATION
TACH BLACK WHITE

BLACK LEAD LEAD
5 6 7 8
1 2 3 4
TACH TACH
RED BLUE
LF-72/74

F-9 TROUBLESHOOTING AND REPAIR F-9
GAS SOLENOID TEST

WARNING
TEST DESCRIPTION
This test will determine if the gas solenoid is receiving the correct voltage and if the
solenoid is functional.
MATERIALS NEEDED
5/16 in. nut driver
12 VDC @ 1 amp power source
Volt-Ohmmeter
LF-72/74

F-10 F-10
TROUBLESHOOTING AND REPAIR
GAS SOLENOID TEST
(continued)
FIGURE F.2 - GAS SOLENOID FIGURE F.3 – LEADS 552, 552B & 553
Off = 0 VDC
OCV = 59 VDC
On = 7.7 VDC
GAS SOLENOID
553
Located on
case back
Coil
measures
21 ohms
GAS
SOLENOID 552
552B
TEST PROCEDURE 6. If the 8VDC is missing or low, check

the leads and connections between
the solenoid and the control board.
1. Remove the input power from the
See the wiring diagram. If the leads
LF72/LF74 unit.
and connections are ok, the control
board may be faulty.
2. Using the 5/16 nut driver, remove the
5 screws holding the cover.
7. Normal solenoid coil resistance is 21
ohms.
3. Locate the gas solenoid (FIG F.2) on
the back of the feeder.
8. The solenoid can be further checked
by disconnecting the leads and
4. Apply the correct (42VAC) input applying 12VDC directly to the
voltage to the unit. terminals. If the solenoid does not
activate the solenoid is faulty.
5. While pressing the gas purge button

or activating the gun trigger, check for 9. Reconnect the leads and replace the
approximately 8VDC at the solenoid cover.
leads (FIG F.3). If the 8VDC is
present the solenoid should activate.
If the 8VDC is present but the
solenoid does not activate the
solenoid may be faulty.
LF-72/74

F-11 F-11
DIODE BRIDGE TEST

WARNING
TEST DESCRIPTION
This test will help determine if the diode bridge is receiving the power AC input voltages
and is converting them to the correct DC output voltages.
MATERIALS NEEDED
5/16 in. nut driver

42VAC power supply
Volt-Ohmmeter
LF-72/74

F-12 F-12
DIODE BRIDGE TEST
(continued)
FIGURE F.4 – CONTACTOR
552B
+
552A
41
580 42
TEST PROCEDURE 4. Check for the correct input voltage at

leads 41 and 42 on the bridge. If
the input voltage is not there check
1. Remove the input power from the
the wiring back to the receptacle
unit.
assembly pins I and K.
2. Using a 5/16 nut driver remove the 5

5. Check for the proper output on leads
screws holding the cover.
580 negative and 522 positive. The
voltage should be 59VDC. If you are

3. Apply the correct input voltage only reading 38VDC the control circuit
(42VAC) to the LF72/LF74 unit. is open. Check the wiring and the
connections back to your control
board.
LF-72/74

F-13 F-13
WIRE SPEED POTENTIOMETER TEST

WARNING
TEST DESCRIPTION
This test will help determine if the wire speed potentiometer is receiving and sending
the correct voltages..
MATERIALS NEEDED
5/16 in. nut driver

42VAC power supply
Volt-Ohmmeter
LF-72/74

F-14 F-14
WIRE SPEED POTENTIOMETER TEST (Continued)
Figure F.5
577 WIRE FEED

576 SPEED
10K/2W
CONTROL
575 POTENTIOMETER
0 VDC MIN. WFS

5 VDC MIN. WFS
TEST PROCEDURE
1. Remove the input power from the unit. 6. The potentiometer can also be
checked by unplugging the P8
2. Using 5/16 nut driver remove the 5 connection (see wiring diagram), and
screws holding the cover. checking for 0 to 10k ohms between
leads 575 and 576 (as pot is located).
3. Apply the correct input voltage
(42VAC) to the LF72/LF74 unit. 7. Reconnect the disconnected leads and
reassemble the cover.
4. Locate the P8 plug (see wiring
diagram) going to the potentiometer.
5. Check for 0VDC minimum to 5VDC

maximum between wires 575 and 576.

If the voltage is not there, check the
wires for continuity back to the control
board. If the wiring checks out good,
the control board may be faulty.
LF-72/74

F-15 F-15
PC BOARD REMOVAL AND REPLACEMENT

WARNING
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the control pc
board.
MATERIALS NEEDED
5/16 in. nut driver

3/8 in. nut driver
Anti-static strap
LF-72/74

F-16 F-16
CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE
(Continued)
Figure F.6 - PC Board Location
CONTROL BOARD
REMOVAL PROCEDURE REPLACEMENT PROCEDURE

1. Remove the new control board from the
static bag and place it on the 4 studs.
1. Remove the input power ( 42VAC )
from the LN72/LN74 unit. 2. Reassemble the 4 nuts and tighten hand
tight.
2. Using the 5/16 nut driver remove the 5
screws holding the cover. 3. Reassemble the harness plugs.
3. Locate the control board (see figure F.6) 4. Reassemble the case.
and remove the harness plugs on the

control board. Observe static electricity

precautions.
4. Remove the 4 nuts holding the board

using the 3/8 inch nut driver, and remove
the board.
LF-72/74

F-17 F-17
WIRE DRIVE MOTOR AND GEAR BOX
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the drive
motor or the gear box.
MATERIALS NEEDED
5/16 in. nut driver

7/16 in. socket wrench and extension
3/4 in. wrench
Phillips head screw driver
Pliers
LF-72/74

F-18 F-18
WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT
PROCEDURE (Continued)
Figure F.7 - Wire Drive Motor(s)
MOUNTING SCREWS * MOUNTING BOLTS

INCOMING
BUSHING
BALL
BUSHING
ASSEMBLY
O-RING
SET SCREW
MOUNTING SCREWS*
*REMOVE 6 MOUNTING SCREWS
PROCEDURE 6. Using the 3/4 inch wrench remove the

electrode cable from the connector
1. Remove th input power from the block.
LF72/LF72 unit.
7. Remove the tach and motor leads by
2. Remove the gun from the unit. disconnecting the P10 connector. See
wiring diagram.
3. Using the 5/16 nut driver remove the 5
screws holding the cover. 8. Using the 7/16 inch socket wrench and
extension remove the six mounting
4. Using the Phillips head screw driver
bolts. See figure F.7. The motor, and
remove the #67 electrode sense lead
gear box assembly can now be
from the connection block.
removed from the LF72/LF74 unit.
5. Using the pliers remove the gas hose
from the connection block. Be careful
not to damage the hose.
LF-72/74

F-19 F-19
REMOVAL OF THE DRIVE REMOVAL OF THE GEAR BOX

MOTOR FROM THE GEAR BOX FROM THE MOUNTING PANEL.
1. Using the 7/16 in. wrench remove the 6. Follow the first five steps found in the
cover from the gear box. See Figure F.7. drive motor removal.
note the LF72 only has one screw.
7. Using the 7/16 wrench remove the four
2. Loosen and remove the outer wire guide. bolts holding the gear box to the panel.
3. Loosen and remove the drive roll

assembly. The LF72 has one while the
LF74 has three.
4. Using the Phillips head screw driver

remove the gear drive. See Figure F.7.
5. Using the phillips head screw driver
remove the three screws holding the
drive motor. See Figure F.7.
LF-72/74


REPLACEMENT PROCEDURES 6. Feed the gas hose, and the # 67 lead

through the notch on the panel. Feed the
P10 plug through the center panel. Align
and mount and tighten the panel using
1. Line up the gear box with the 4 holes on the six lock washers and bolts previously
the panel. Replace and tighten the four removed.
1/4-20 x 1/2 in. hex head bolts.
7. Plug the P10 plug into the wiring
2. Insert the drive motor through the panel harness.
and gear box. Line up and tighten the
three M6 x 1.00 in. Phillips pan head 8. Using the Phillips head screw driver
screws. connect the #67 electrode sense lead to
the connector block.

3. Replace the drive gear and secure in

place using the screw and lock washer 9. Using the 3/4 in. wrench connect the
previously removed. electrode lead to the connector block.
4. Replace the drive rolls and secure the 10. Connect the gas hose.
secure locking rings.
11. Install the cover using the five screws.
5. Replace the gear box cover and secure
with the 1/4-20 hex head screws. 12. Connect the gun.
LF-72/74

RETEST AFTER REPAIR
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any part which
could affect the machine’s electrical characteristics.
OR
• If you repair or replace any electrical components.
SET UP
1. Connect a supply of filtered compressed air at 80 psi to the gas inlet.

2. Supply 42VAC to the machine.
3. Connect the gun to the connector block.
OPERATION VERIFICATION
1. Close the idle arms and the pressure arms.

2. Activate the cold feed switch.
3. Verify the drive rolls are spinning in the forward direction.
4. Adjust the wire speed knob from min to max and verify the speed is changing.
5. Release the cold feed switch and verify that the drive rolls stop abruptly.
6. Activate the gas purge switch and verify that there is gas flow.
7. Release the gas purge switch and verify the gas flow stops.
8. Place the 2-step/trigger interlock switch in the trigger interlock position.

9. Activate the gun trigger and verify the drive rolls spin.
10. Release the gun trigger and verify the drive rolls continue to spin.
11. Activate and release the gun trigger and verify the drive rolls stop abruptly.
12. Place the 2-step/trigger interlock switch in the 2-step position.
LF-72/74

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-22

LF-72/74
NOTES
F-22
Section G-1 TABLE OF CONTENTS Section G-1
- ELECTRICAL DIAGRAMS SECTION -

Electrical Diagrams........................................................................................................................Section G
Wiring Diagram - Entire Machine - Code 11075, 11076, 11077 - (L12146) LF-72 ...........................G-2
Wiring Diagram - Entire Machine - Code 11209, 11210, 11211, 11227 - (L12146-1) LF-72 ............G-3
Wiring Diagram - Entire Machine - Code 11290, 11291, 11292, 11293 - (L12146-2) LF-72 ............G-4
Wiring Diagram - Entire Machine - Code 11195, 11196, 11197 - (L12484) LF-74 ............................G-5
Schematic - Entire Machine - Code 11075, 11076, 11077 - (G4617) LF-72 ....................................G-6
Schematic - Entire Machine - Code 11209, 11210, 11211, 11227 - (G4617-1) LF-72......................G-7
Schematic - Entire Machine - Code 11290, 11291, 11292, 11293 - (G4617-2) LF-72 .....................G-8
Schematic - Entire Machine - Code 11195, 11196, 11197 - (G4942) LF-74 .....................................G-9
Schematic - Common Analog Control PC Board - (G4559 Sheet 1) ..............................................G-10
PC Board Assembly - Common Analog Control - (G4560-2E0) .....................................................G-13
LF-72/74

G-2 ELECTRICAL DIAGRAMS G-2
WIRING DIAGRAM - ENTIRE MACHINE - CODE 11075, 11076, 11077 (L12146) LF-72
GENERAL INFORMATION
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
ELECTRICAL SYMBOLS PER E1537 575 1 575A 577A
3
WIRE FEED
576 2 576A
COLOR CODE 576A 2 10K/2W SPEED
577 3 577A
1 1 2 1 3
B- BLACK 1 CONTROL
J3 J7 4
J2
W- WHITE
575A POTENTIOMETER
2 3 4 4 6 5
R- RED 6 N.C.
1 4 1 8 U- BLUE
J5,J8
J1,J14 P8
J9,J60
5 8 9 16
N.B.
77
75A 1 75 REMOTE
3 CONTROL
76A 2 76 76 2 10K/2W
VOLTAGE
1
77A 3 77 POTENTIOMETER
75 (OPTIONAL)
552B INPUT ELECTRODE 4 N.C.
552 L2
67
CABLE CONNECTION
P7
N.B.
FEED
GAS PLATE
SOLENOID
553
TACH POST-FLOW BURNBACK

TIMER KIT
R J60 (OPTIONAL)
U MOTOR /
1
B
GEARBOX
2
1 2 3 4 5 6 7 8
563 3
562 4 601 515A 605 607
552B B W 606A 608
41A 575B 5
BAFFLE
MOUNTED 6
RECTIFIER 551 7 B N.A.
DIODE
550 8 W
BRIDGE
552A P5
+
552C
N.B. P9
TRIGGER
- INPUT
L4 L5
556 A
1 2 3 4 5 6 7 8 9 10
41 580 42 B
575
554 TRIGGER
C
575B
50 41A 51 552C CONNECTOR
D
14 PIN 575C J4
AMPHENOL E
CONNECTOR
606A
TO POWER L1 N.B.
SOURCE
B
A
L3 N.D.
606
B
OUTPUT C 2
CONTROL
D 4 THERMAL LED
E 77A
REMOTE W B
VOLTAGE F 76A
CONTROL
G 75A
H COLD FEED
I 41
42VAC ARC J 50
CURRENT
K 42 558
ARC VOLTAGE L 51 580 4 2 515A
515 S1
M 577 575C 576
SENSE N 67 550 551 563 587 608 558 601 589 559
COMMON ANALOG P.C. BOARD K
562 554 552A 553 556 552 E 559 515
J6 605 607 W Y 606
N.C. GAS PURGE
N.B.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
TRIGGER
INTERLOCK
J1 J2 J3 J14
589
S2
587
2-STEP
NOTES: N.C.
N.A.
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. TOGGLESWITCHES AND POTENTIOMETERS SHOWN FROM CONNECTION SIDE OF SWITCH.
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS ALIGNS WITH WHITE LEAD OF LED SOCKET.
A
L12146
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
LF-72/74

WIRING DIAGRAM - ENTIRE MACHINE - CODE 11209, 11210, 11211,11227 (L12146-1) LF-72
GENERAL INFORMATION
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
ELECTRICAL SYMBOLS PER E1537 575 1 575A 577A
3
WIRE FEED
576 2 576A
COLOR CODE 576A 2 10K/2W SPEED
577 3 577A
1 1 2 1 3
B- BLACK 1 CONTROL
J3 J7 4
J2
W- WHITE
575A POTENTIOMETER
2 3 4 4 6 5
R- RED 6 N.C.
1 4 1 8 U- BLUE
J5,J8
J1,J14 P8
J9,J60
5 8 9 16
N.B.
77
75A 1 75 REMOTE
3 CONTROL
76A 2 76 76 2 10K/2W
VOLTAGE
1
77A 3 77 POTENTIOMETER
75 (OPTIONAL)
552B INPUT ELECTRODE 4 N.C.
552 L2
67
CABLE CONNECTION
P7
N.B.
FEED
GAS PLATE
SOLENOID
553
TACH POST-FLOW BURNBACK

TIMER KIT
R J60 (OPTIONAL)
U MOTOR /
1
B
GEARBOX
2
1 2 3 4 5 6 7 8
563 3
562 4 601 515A 605 607
552B B W 606A 608
575B 5
BAFFLE
MOUNTED 6
RECTIFIER 551 7 B N.A.
DIODE
550 8 W
BRIDGE
P5
+
552A
N.B.
TRIGGER
- INPUT
L4 L5
556 A
41 580 42 B
575
554 TRIGGER
C
575B CONNECTOR
D
14 PIN 575C J4
AMPHENOL E
CONNECTOR
606A
TO POWER L1 N.B.
SOURCE
B
A
L3 N.D.
606
B
OUTPUT C 2
CONTROL
D 4 THERMAL LED
E 77A
REMOTE W B
VOLTAGE F 76A
CONTROL
G 75A
H COLD FEED
I 41
42VAC J
K 42 558
L 580 4 2 515A
515 S1
M 577 575C 576
SENSE N 67 550 551 563 587 608 558 601 589 559
COMMON ANALOG P.C. BOARD K
562 554 552A 553 556 552 E 559 515
J6 605 607 W Y 606
N.C. GAS PURGE
N.B.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
TRIGGER
INTERLOCK
J1 J2 J3 J14
589
S2
587
2-STEP
NOTES: N.C.
N.A.
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF BOARD.
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF CONNECTOR.
N.C. TOGGLESWITCHES AND POTENTIOMETERS SHOWN FROM CONNECTION SIDE OF SWITCH.
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS ALIGNS WITH WHITE LEAD OF LED SOCKET.
A
L12146-1
LF-72/74

WIRING DIAGRAM - ENTIRE MACHINE - CODE 11290, 11291, 11292,11293 (L12146-2) LF-72
CAVITY NUMBERING SEQUENCE GENERAL INFORMATION

(COMPONENT SIDE OF P.C. BOARD) 577
ELECTRICAL SYMBOLS PER E1537 3
WIRE FEED
1 1 2 1 3
576 2 10K/2W SPEED
J3 J7 J2
COLOR CODE 1 CONTROL
2 3 4 4 6
B- BLACK
575 POTENTIOMETER
W- WHITE
J5,J8
1 4 1 8
R- RED N.C.
J1,J14
J9,J60 U- BLUE
5 8 9 16
77
75A 1 75 REMOTE
3 CONTROL
76A 2 76 76 2 10K/2W VOLTAGE
1 POTENTIOMETER
77A 3 77
75 (OPTIONAL)
4 N.C.
1 1 L2
552B
B INPUT ELECTRODE P7
552
2 2 67
CABLE CONNECTION N.B.
A 3 3 551A
GAS
4 4 FEED
SOLENOID PLATE
553
P11 P4
TACH
R
POST-FLOW BURNBACK
U MOTOR / J60
B
GEARBOX TIMER KIT
(OPTIONAL)
1 2 3 4 5 6 7 8
552B B W
601 515A 605 607
606A 608
1 521
BAFFLE N.A.
MOUNTED 2 522
RECTIFIER
DIODE
+
3 551B
BRIDGE 551A
4 P10
551B
N.E.
- 1
P6
2
551
41 580 42 L6 563 3 R
L4 562 4 U
575B 5 B
552A 6 N.B.
575 L5 TRIGGER
551 7 B
575B
14 PIN 550 8 W INPUT
575C
CIRCULAR 556 A
CONNECTOR B
TO POWER L1 554 TRIGGER
C
SOURCE N.B. CONNECTOR
D
J13
A E
606A
B
OUTPUT C 2 1B
CONTROL
D 4
E 77A L3 606
REMOTE
VOLTAGE
CONTROL
F 76A N.D.
G 75A
H
THERMAL LED
I 41
42VAC J 1W 1B
K 42
L
M 577 575C 576 4 COLD FEED
SENSE N 67
2
558
J12 580 515A
550 A 563 521 587 608 1W 558 601 589
K 515 S1
N.B. 562 554 552A 553 556 552 522 E 559 515
605 607 Y 606 559
NOTES:
N.C. GAS PURGE
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
OF BOARD. TRIGGER
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF INTERLOCK
CONNECTOR. J1 J2 J3 J14
N.C. TOGGLESWITCHES AND POTENTIOMETERS SHOWN FROM COMMON ANALOG P.C. BOARD 589
S2
CONNECTION SIDE OF SWITCH. 587
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS ALIGNS WITH WHITE LEAD
OF LED SOCKET. N.A.
2-STEP
N.E. P6 NOT USED. N.C.
A
L12146-2
LF-72/74

WIRING DIAGRAM - ENTIRE MACHINE - CODE 11195, 11196, 11197, (L12484) LF-74
CAVITY NUMBERING SEQUENCE GENERAL INFORMATION

(COMPONENT SIDE OF P.C. BOARD) 577
ELECTRICAL SYMBOLS PER E1537 3
WIRE FEED
1 1 2 1 3
576 2 10K/2W SPEED
J3 J7 J2
COLOR CODE 1 CONTROL
2 3 4 4 6
B- BLACK
575 POTENTIOMETER
W- WHITE
J5,J8
1 4 1 8
R- RED N.C.
J1,J14
J9,J60 U- BLUE
5 8 9 16
77
75A 1 75 REMOTE
3 CONTROL
76A 2 76 76 2 10K/2W VOLTAGE
1 POTENTIOMETER
77A 3 77
75 (OPTIONAL)
NORMAL SPEED 4 N.C.
1 1 L2
552B
B INPUT ELECTRODE P7
552
2 2 67
CABLE CONNECTION N.B.
A 3 3 551A
GAS
4 4 FEED
SOLENOID PLATE
N.E. P11 P4
553
TACH
R
POST-FLOW BURNBACK
U MOTOR / J60
B
GEARBOX TIMER KIT
(OPTIONAL)
1 2 3 4 5 6 7 8
552B B W
601 515A 605 607
606A 608
HIGH TORQUE
1 1 521
BAFFLE B N.A.
MOUNTED 2 2 522
RECTIFIER
DIODE
+
A 3 3 551B
BRIDGE 551A
4 4 P10
551B
-
N.E. P11 P6
1
2
551
41 580 42 L6 563 3 R
L4 562 4 U
575B 5 B
552A 6 N.B.
575 L5 TRIGGER
551 7 B
575B
14 PIN 550 8 W INPUT
575C
AMPHENOL 556 A
CONNECTOR B
TO POWER L1 554 TRIGGER
C
SOURCE N.B. CONNECTOR
D
J13
A E
606A
B
OUTPUT C 2 1B
CONTROL
D 4
E 77A L3 606
REMOTE
VOLTAGE
CONTROL
F 76A N.D.
G 75A
H
THERMAL LED
I 41
42VAC J 1W 1B
K 42
L
M 577 575C 576 4 COLD FEED
SENSE N 67
2
558
J12 580 515A
NOTES: 550 A 563 521 587 608 1W
K 558 601 589
515 S1
N.B. 562 554 552A 553 556 552 522 E 559 515
605 607 Y 606 559
N.A. CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE
OF BOARD.
N.C. GAS PURGE
N.B. CAVITY NUMBERING SEQUENCE AS VIEWED FROM LEAD SIDE OF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CONNECTOR.
TRIGGER
N.C. TOGGLESWITCHES AND POTENTIOMETERS SHOWN FROM INTERLOCK
CONNECTION SIDE OF SWITCH. J1 J2 J3 J14
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS ALIGNS WITH WHITE LEAD COMMON ANALOG P.C. BOARD 589
OF LED SOCKET. S2
587
N.E. PLACE P11 IN APPROPRIATE POSITION FORSPEED OR TORQUE.
CONNECTION SHOWN IS FOR NORMAL SPEED. NOTE: NORMAL SPEED N.A.
2-STEP
NOT AVAILABLE ON HIGH TORQUE MODEL. HIGH TORQUE NOT AVAILABLE ON
N.C. A
NORMAL SPEED MODEL.
L12484
LF-72/74

SCHEMATIC - ENTIRE MACHINE - CODE 11075, 11076, 11077 (G4617) LF-72
Values for CV300. Others

may be different.
0 VDC @ 0 = 5.8 Arc Volts
6.6 VDC @ 10 = 40 ArcVolts
REMOTE
75A 1 75
CONTROL
76A 2 76 10K/2W VOLTAGE
POTENTIOMETER
77A 3 77
(OPTIONAL)
Connector located 4
behind case front
P7
577 3 577A
576A
WIRE FEED
576 2 10K/2W
575 1 575A
SPEED
Connector located Gearbox ratio is 2:47 CONTROL
Motor is at electrode Motor resistance 4
POTENTIOMETER
by sheet panel is 1.5 ohms 5 0 VDC MIN. WFS
potential 5 VDC MIN. WFS
1 6
575 Motor is located
Off = 0 VDC 2 behind
OCV = 59 VDC 575B L4 P8
563 3 glastic panel
On = 7.7 VDC 575C 4
FEED Connector located
562 562 PLATE
MOTOR / behind case front
563 575B 5 GEARBOX
553
Located on 6
Coil case back 551 7 B

measures 550 8 W To Power Source Electrode Connection
21 ohms GAS 1.6V @ 50 IPM
P5
SOLENOID 30.6V @ 800 IPM
552 67
552B
L2 TRIGGER
INPUT
556 A
Plug for future Located behind 554

B
TRIGGER
run-in kit. P9 front panel C
CONNECTOR
D
J4
15V SIGNAL E
b D 100 msec PULSES
1 2 3 4 5 6 7 8 9 10 552B
POSTFLOW TOGGLE GAS FLOW ON/OFF
Located on POSTFLOW
TIME RANGE
50 41A 51 552C internal panel .25 - 10 SEC
POT.
552C A c
41A 5V SIGNAL
FIXED c D COM
GAS FLOW
PULSE PREFLOW & ENABLE Located on
WIDTH
Start-Up POSTFLOW TIMER
TIMER KIT Case Front
+
GENERATOR +15V
OUTPUT
552A LOGIC
On power-up, the LF-72 will light the (OPTIONAL) THERMAL LED
INPUT
BURNBACK
motor thermal LED for 0.5 seconds. A b
POT SCHEMATIC =
PREFLOW
-
L5 TIME FIXED COM J60-6 J60-5 J60-8 J60-7 J60-1 J60-3 M20336 Lights when motor
If the feeder is powered-up with the AT 30msec 5 VDC
trigger depressed, welding will not start when lit current exceeds 4
41 580 42 Located on 606A
601 B W Amps for an
until the trigger is released and then Timer Board Summary Case Front 605
608 607
depressed again.
515A extended time.
• Has potentiometers for burnback and postflow. B
• Preflow fixed at 30msec. 15 VDC Open

J6 L1
COLD FEED
• Burnback range is 0 to 0.25 sec. 0 VDC Closed
Located on
ARC CURRENT J 50 • Postflow range is 0.25 to 10 sec. 558
Case Front
ARC VOLTAGE 515A
L 51
41
• Receives “Gas Flow Enable” signal. 515 S1
I
24-42VAC
K 42 • Outputs 100 msec pulses to turn Gas Flow On, Gas L3 559
REMOTE
E 77A Flow Off.
VOLTAGE F 76A 15 VDC Open GAS PURGE
CONTROL
G 75A
0 VDC Closed
SENSE N 67 20 OHM = OUTPUT ENABLED
HIGH IMPEDANCE = OUTPUT DISABLED TRIGGER
M INTERLOCK
C 2 Located on
OUTPUT
CONTROL D 4 589 Case Front
575C MOLEX S2
587
552 INDEX
38VDC at 576
KEY
Trigger Interlock does not
552A 563 558
42VAC input 577 551 556
NOT USED NOT USED
4 605
601
W 589 2-STEP stop welding when the
550 554
with control 580 553 562 608 515 587 arc is broken. Pull and
board
2 606 607 559 15 VDC in release to end the weld.
disconnected. 2 STEP
position
60VDC with +15V
J1-2 J1-6 J1-16 J1-8 J1-3 J1-13 J1-9 J1-1 J1-15 J1-12 J1-5 J1-11 J1-4 J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 J3-1 J3-2 J14-1 J14-9 J14-8 J14-14 J14-2 J14-5 J14-4 J14-12 J14-13 J14-7 J14-10 J14-16 J14-11 J14-15 J14-3
control board 750 ohm +15V
connected +POWER 100K 20
ohm ohm
MOV
+5V +5V OPEN = 0V
COM 750 ohm MACHINE
CLOSED = 8V
TRIGGER OUTPUT
ENABLE +15V +15V
+5V
BOARD
POWER MOTOR
SUPPLY VOLTAGE
+ POWER SENSE 0V = 0.02 SECONDS
Control Board Summary BURNBACK 5V = 0.25 SECONDS
• Has on-board power supply. DRIVE
FET MOTOR
• Receives switch signals from Trigger, Cold Feed, Gas Purge, Trigger DRIVE
Interlock BRAKE
CIRCUIT
COM EXTERNAL
• Reads WFS potentiometer. FET
GAS LOW = CONTROL AT CONTROL BOARD
• Communicates with optional timer kit to control burnback, postflow. SOLENOID HIGH = CONTROL AT TIMER BOARD
CONTROL
• Controls motor speed with PWM. MOTOR
CURRENT
• Turns Gas Solenoid on, off. SENSE
SCALING MICRO
• Monitors motor current, lights yellow thermal LED if over 4 amps for an 0.1 ohm CONTROLLER
extended time period. LED remains lit for 30 – 60 seconds to allow motor DO NOT USE
to cool. PROGRAM NOT FIELD PROGRAMMABLE
• Does NOT support Run-in at this time. TACH
0-5V PULSE SIGNAL FEEDBACK
• Operates on 24-42 VAC. Maximum WFS and/or maximum pull force may FILTER
FREQUENCY = SPEED (NOT ACTIVE)
5V = OFF 200 ohm
THERMAL 4V OR LESS = ON
be less when operating at 24 VAC. LED
• Does NOT operate on 115 VAC. 0V = MIN SPEED WIRE
LOW = DISABLE
5V = MAX SPEED FEED GAS HIGH = ENABLE
SPEED
PURGE
SOLENOID 200 ohm LOW = DISABLE

GAS
FET COLD HIGH = ENABLE
SOLENOID
FEED
0.25
10K ohm
ohm
LOW = DISABLE
TRIGGER HIGH = ENABLE
INTERLOCK
COMMON ANALOG P.C. BOARD

SCHEMATIC = G4559
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
LF-72/74

SCHEMATIC - ENTIRE MACHINE - CODE 11209, 11210, 11211,11227 (G4617-1) LF-72

may be different.
REMOTE
75A 1 75
CONTROL
76A 2 76 10K/2W VOLTAGE
POTENTIOMETER
77A 3 77
(OPTIONAL)
Connector located 4
behind case front
P7
577 3 577A
576A
WIRE FEED
576 2 10K/2W
575 1 575A
SPEED
Motor is at electrode Motor resistance 4
POTENTIOMETER
by sheet panel is 1.5 ohms 5 0 VDC MIN. WFS
potential 5 VDC MAX. WFS
1 6
575 Motor is located
Off = 0 VDC 2 behind
OCV = 59 VDC 575B L4 P8
563 3 glastic panel
On = 7.7 VDC 575C 4
FEED Connector located
562 562 PLATE
MOTOR / behind case front
563 575B 5 GEARBOX
553
Located on 6

P5
SOLENOID 30.6V @ 800 IPM
552 67
552B
L2 TRIGGER
INPUT
556 A
B
554 TRIGGER
C
CONNECTOR
D
J4
15V SIGNAL E
b D 100 msec PULSES
552B
Located on POSTFLOW
TIME RANGE
internal panel .25 - 10 SEC
POT.
A c
5V SIGNAL
FIXED c D COM
GAS FLOW
PULSE PREFLOW & ENABLE Located on
WIDTH
Start-Up POSTFLOW TIMER
TIMER KIT Case Front
+
GENERATOR +15V
OUTPUT
552A LOGIC
On power-up, the LF-72 will light the (OPTIONAL) THERMAL LED
INPUT
BURNBACK
motor thermal LED for 0.5 seconds. A b
POT SCHEMATIC =
PREFLOW
-
L5 TIME FIXED COM J60-6 J60-5 J60-8 J60-7 J60-1 J60-3 M20336 Lights when motor
If the feeder is powered-up with the AT 30msec 5 VDC
trigger depressed, welding will not start when lit current exceeds 4
41 580 42 Located on 606A
601 B W Amps for an
until the trigger is released and then Timer Board Summary Case Front 605
608 607
depressed again.
515A extended time.
• Has potentiometers for burnback and postflow. B
• Preflow fixed at 30msec. 15 VDC Open

J6 L1
COLD FEED
• Burnback range is 0 to 0.25 sec. 0 VDC Closed
Located on
ARC CURRENT J • Postflow range is 0.25 to 10 sec. 558
Case Front
ARC VOLTAGE 515A
L
41
• Receives “Gas Flow Enable” signal. 515 S1
I
24-42VAC
K 42 • Outputs 100 msec pulses to turn Gas Flow On, Gas L3 559
REMOTE
G 75A Flow Off.
VOLTAGE F 76A 15 VDC Open GAS PURGE
CONTROL
E 77A
0 VDC Closed
SENSE N 67 20 OHM = OUTPUT ENABLED
HIGH IMPEDANCE = OUTPUT DISABLED TRIGGER
M INTERLOCK
C 2 Located on
OUTPUT
S2
575C MOLEX 587

552 INDEX
38VDC at 576
KEY
552A 563 558
42VAC input 577 551 556
NOT USED NOT USED
4 605
601
W 589 2-STEP stop welding when the
550 554
with control 580 553 562 608 515 587 arc is broken. Pull and
board
2 606 607 559 15 VDC in release to end the weld.
position
60VDC with +15V
J1-2 J1-6 J1-16 J1-8 J1-3 J1-13 J1-9 J1-1 J1-15 J1-12 J1-5 J1-11 J1-4 J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 J3-1 J3-2 J14-1 J14-9 J14-8 J14-14 J14-2 J14-5 J14-4 J14-12 J14-13 J14-7 J14-10 J14-16 J14-11 J14-15 J14-3
ohm ohm
MOV
+5V +5V OPEN = 0V
COM 750 ohm MACHINE
CLOSED = 8V
TRIGGER OUTPUT
ENABLE +15V +15V
+5V
BOARD
POWER MOTOR
SUPPLY VOLTAGE
Control Board Summary BURNBACK 5V = 0.25 SECONDS
• Has on-board power supply. DRIVE
FET MOTOR
• Receives switch signals from Trigger, Cold Feed, Gas Purge, Trigger DRIVE
Interlock BRAKE
CIRCUIT
COM +5V EXTERNAL
• Reads WFS potentiometer. +15V FET
• Communicates with optional timer kit to control burnback, postflow. SOLENOID HIGH = CONTROL AT TIMER BOARD
CONTROL
• Controls motor speed with PWM. MOTOR
CURRENT
• Turns Gas Solenoid on, off. SENSE
SCALING MICRO
• Monitors motor current, lights yellow thermal LED if over 3.75 amps for an 0.1 ohm CONTROLLER
extended time period. LED remains lit for 30 – 60 seconds to allow motor DO NOT USE
to cool. PROGRAM NOT FIELD PROGRAMMABLE
• Does NOT support Run-in at this time. TACH
• Operates on 24-42 VAC. Maximum WFS and/or maximum pull force may FILTER
FREQUENCY = SPEED (NOT ACTIVE)
5V = OFF 200 ohm
be less when operating at 24 VAC. LED
• Does NOT operate on 115 VAC. 0V = MIN SPEED WIRE
LOW = DISABLE
5V = MAX SPEED FEED
COLD HIGH = ENABLE

SPEED FEED
SOLENOID 200 ohm LOW = DISABLE

GAS
FET SOLENOID GAS HIGH = ENABLE
PURGE
0.25
10K ohm
ohm
LOW = DISABLE
INTERLOCK

SCHEMATIC = G4559
LF-72/74

SCHEMATIC - ENTIRE MACHINE - CODE 11290, 11291, 11292,11293 (G4617-2) LF-72

may be different.
REMOTE
75A 1 75
CONTROL Located on
76A 2 76 10K/2W VOLTAGE Case Front
POTENTIOMETER
77A 3 77
(OPTIONAL)
Connector located 4
behind case front
P7
577
576
WIRE FEED Located on
10K/2W
575
SPEED Case Front
Motor is at electrode Motor resistance POTENTIOMETER
by sheet panel is 1.5 ohms 0 VDC MIN. WFS
Leads Pass through potential 5 VDC MIN. WFS
1
575
toroid 2 times. Motor is located
Off = 0 VDC 2
R
behind
OCV = 59 VDC 575B L4 U
563 3 glastic panel
On = 7.7 VDC 575C 4
FEED
562 562 B PLATE
MOTOR /
563 575B 5 GEARBOX
553
Located on 6

SOLENOID P10 30.6V @ 800 IPM
552 67
552B
L2 TRIGGER Located on
Leads Pass through
Case Front
toroid 3 times. INPUT

Leads 556 A
Pass
B
through 554 TRIGGER
C
toroid 2 Located on Case Front CONNECTOR
times. D
J13
15V SIGNAL E
b D
552B 100 msec PULSES Timer Board Summary
Located on L5 TIME RANGE
POSTFLOW • Has potentiometers for burnback and postflow.
POT.
Sheet Panel .25 - 10 SEC A c • Preflow fixed at 30msec.
5V SIGNAL
551 FIXED c D GAS FLOW
COM • Burnback range is 0 to 0.25 sec. Located on
PULSE PREFLOW &
WIDTH POSTFLOW TIMER
ENABLE • Postflow range is 0.25 to 10 sec. Case Front
TIMER KIT
+
GENERATOR +15V • Receives “Gas Flow Enable” signal.
OUTPUT
552A LOGIC
(OPTIONAL) THERMAL LED
INPUT
Connector located A b BURNBACK • Outputs 100 msec pulses to turn Gas Flow On, Gas
on sheet panel PREFLOW POT SCHEMATIC =
-
TIME FIXED M20336 Flow Off.
AT 30msec
COM J60-6 J60-5 J60-8 J60-7 J60-1 J60-3
5 VDC Lights when motor
when lit current exceeds
41 580 42 606A 1B
608 607 601 1W 3.75 Amps for an
522 605
Leads Pass 551A
515A extended time.
551B 1B
through 521 Connector located
toroid 2 times. behind sheet panel Leads Pass 15 VDC Open
J12 L1 P4 1 2 3 4 P6 1 2 3 4 COLD FEED
through 0 VDC Closed
toroid 2 Located on
J 558
P11 1 2 3 4
times. Case Front
L 515A
I 41 515 S1
24-42VAC
K 42
B Motor Connecter Summary L3 559
Located on REMOTE
G 75A • P6 not used – required for LF-74
Case Back 76A Leads Pass GAS PURGE
VOLTAGE
CONTROL
F
575C through A only.. 15 VDC Open
E 77A
0 VDC Closed
SENSE N 67 toroid 2
576
562 times. L6 TRIGGER
M 563 INTERLOCK
C 2 Located on
OUTPUT
556 20 OHM = OUTPUT ENABLED MOLEX S2
587
554 522 HIGH IMPEDANCE = OUTPUT DISABLED

552 INDEX
38VDC at KEY
552A 577 558
42VAC input 521 NOT USED NOT USED
4 605
601
1W 589 2-STEP stop welding when the
with control 580 553 608 515 587 arc is broken. Pull and
board
A 2 606 607 559 15 VDC in release to end the weld.
550
position
60VDC with J1-3 J1-13 J1-9
+15V
J1-2 J1-6 J1-16 J1-8 J1-1 J1-15 J1-12 J1-5 J1-11 J1-4 J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 J3-1 J3-2 J14-1 J14-9 J14-8 J14-14 J14-2 J14-5 J14-4 J14-12 J14-13 J14-7 J14-10 J14-16 J14-11 J14-15 J14-3
ohm ohm
MOV
COM
+5V +5V 750 ohm
OPEN = 0V
CLOSED = 8V
MACHINE Start-Up
TRIGGER OUTPUT On power-up, the LF-72 will light the motor
ENABLE +15V +15V
thermal LED for 0.5 seconds.
+5V
BOARD
POWER MOTOR If the feeder is powered-up with the trigger
SUPPLY VOLTAGE depressed, welding will not start until the
5V = 0.25 SECONDS
trigger is released and then depressed
BURNBACK again.
DRIVE
FET MOTOR
DRIVE
CIRCUIT Notes
BRAKE
COM +5V +15V FET EXTERNAL The WFS range of the LF-72 is 50-800 ipm.
SOLENOID HIGH = CONTROL AT TIMER BOARD
CONTROL
MOTOR
CURRENT
SENSE
SCALING MICRO
Control Board Summary
0.1 ohm CONTROLLER
DO NOT USE • Has on-board power supply.
PROGRAM NOT FIELD PROGRAMMABLE • Receives switch signals from Trigger, Cold Feed, Gas Purge, Trigger
TACH Interlock
FILTER
FREQUENCY = SPEED 5V = OFF 200 ohm • Reads WFS potentiometer.
LED • Communicates with optional timer kit to control burnback, postflow.
0V = MIN SPEED WIRE
FEED
LOW = DISABLE • Controls motor speed with PWM.
5V = MAX SPEED HIGH = ENABLE
SPEED COLD • Turns Gas Solenoid on, off.
FEED
• Reads the motor tachometer.
200 ohm
• Monitors motor current, lights yellow thermal LED if over 3.75 amps for an
SOLENOID LOW = DISABLE
FET
GAS
SOLENOID
GAS HIGH = ENABLE extended time period. LED remains lit for 30 – 60 seconds to allow motor
0.25
PURGE to cool.
10K ohm • Does NOT support Run-in at this time.
ohm
LOW = DISABLE • Operates on 24-42 VAC. Maximum WFS and/or maximum pull force may
INTERLOCK be less when operating at 24 VAC.
• Does NOT operate on 115 VAC.
SCHEMATIC = G4559
LF-72/74

SCHEMATIC - ENTIRE MACHINE - CODE 11195, 11196, 11197, (G4942) LF-74

may be different.
REMOTE
75A 1 75
CONTROL Located on
76A 2 76 10K/2W VOLTAGE Case Front
POTENTIOMETER
77A 3 77
(OPTIONAL)
Connector located 4
behind case front
284 pulses/sec @ 100 IPM P7
1139 pulses/sec @ 400 IPM
577
576
WIRE FEED Located on
10K/2W
575
SPEED Case Front
Motor is at electrode Motor resistance POTENTIOMETER
by sheet panel is 1.5 ohms 0 VDC MIN. WFS
Leads Pass through potential 5 VDC MIN. WFS
1
575
toroid 2 times. Motor is located
Off = 0 VDC 2
R
40 pole behind
OCV = 59 VDC 575B L4 U ring
563 3
magnet glastic panel
On = 7.7 VDC 575C 4
FEED
562 562 B PLATE
MOTOR /
563 575B 5 GEARBOX
553 5 VDC
Located on 6

SOLENOID P10 30.6V @ 800 IPM
552 67
552B
L2 TRIGGER Located on
Leads Pass through
Case Front
toroid 3 times. INPUT

Leads 556 A
Pass
B
through 554 TRIGGER
C
toroid 2 Located on Case Front CONNECTOR
times. D
J13
15V SIGNAL E
b D
552B 100 msec PULSES Timer Board Summary
Located on L5 TIME RANGE
POSTFLOW • Has potentiometers for burnback and postflow.
POT.
Sheet Panel .25 - 10 SEC A c • Preflow fixed at 30msec.
5V SIGNAL
551 FIXED c D GAS FLOW
COM • Burnback range is 0 to 0.25 sec. Located on
PULSE PREFLOW &
WIDTH POSTFLOW TIMER
ENABLE • Postflow range is 0.25 to 10 sec. Case Front
TIMER KIT
+
GENERATOR +15V • Receives “Gas Flow Enable” signal.
OUTPUT
552A LOGIC
(OPTIONAL) THERMAL LED
INPUT
Connector located A b BURNBACK
POT SCHEMATIC =
• Outputs 100 msec pulses to turn Gas Flow On, Gas
PREFLOW
- on sheet panel Flow Off.
TIME FIXED COM J60-6 J60-5 J60-8 J60-7 J60-1 J60-3 M20336 Lights when motor
AT 30msec 5 VDC
when lit current exceeds
41 580 42 606A 1B
608 607 601 1W 3.75 Amps for an
522 605
Leads Pass 551A
515A extended time.
551B 1B
through 551A 521 Motor Connecter Summary
toroid 2 times. • High Torque Setting engages Leads Pass 15 VDC Open
J12 L1 P4 1 2 3 4 P6 1 2 3 4 COLD FEED
NORMAL Machine Select by connecting Pins 1 through 0 VDC Closed
toroid 2 Located on
J SPEED and 2 on Connector J2. 558
Case Front
P11 1 2 3 4
P11 1 2 3 4
times.
L 515A
I 41
• High Torque not available on Normal 515 S1
24-42VAC B HIGH B Speed Model.
K 42
TORQUE L3 559
Located on REMOTE
G 75A • Normal Speed Setting not available
Case Back 76A Leads Pass GAS PURGE
VOLTAGE
CONTROL
F
575C through A A
on High Torque Model. 15 VDC Open
E 77A
0 VDC Closed
SENSE N 67 toroid 2
576
562 times. L6 TRIGGER
M 563 INTERLOCK
C 2 Located on
OUTPUT
556 20 OHM = OUTPUT ENABLED MOLEX S2
587
552 554 522 HIGH IMPEDANCE = OUTPUT DISABLED INDEX

38VDC at KEY
552A 577 558
42VAC input 521 NOT USED NOT USED
4 605
601
1W 589 2-STEP stop welding when the
with control 580 553 608 515 587 arc is broken. Pull and
board
A 2 606 607 559 15 VDC in release trigger to end the
550
disconnected. 2 STEP weld.
position
60VDC with J1-3 J1-13 J1-9
+15V
J1-2 J1-6 J1-16 J1-8 J1-1 J1-15 J1-12 J1-5 J1-11 J1-4 J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 J3-1 J3-2 J14-1 J14-9 J14-8 J14-14 J14-2 J14-5 J14-4 J14-12 J14-13 J14-7 J14-10 J14-16 J14-11 J14-15 J14-3
ohm ohm
MOV
COM
+5V +5V 750 ohm
OPEN = 0V
CLOSED = 8V
MACHINE Start-Up
TRIGGER OUTPUT On power-up, the LF-74 will light the
ENABLE +15V +15V
motor thermal LED for 0.5 seconds.
+5V
BOARD
POWER MOTOR If the feeder is powered-up with the
SUPPLY VOLTAGE trigger depressed, welding will not start
5V = 0.25 SECONDS
until the trigger is released and then
BURNBACK depressed again.
DRIVE
FET MOTOR
DRIVE
CIRCUIT Notes
BRAKE
COM +5V +15V FET EXTERNAL The WFS range of this code of LF-74 is
GAS LOW = CONTROL AT CONTROL BOARD 100-800 ipm. The WFS range of the
SOLENOID HIGH = CONTROL AT TIMER BOARD
CONTROL
LF-72 is 50-800 ipm.
MOTOR
CURRENT
SENSE
SCALING MICRO
Control Board Summary
0.1 ohm CONTROLLER
DO NOT USE • Has on-board power supply.
PROGRAM NOT FIELD PROGRAMMABLE • Receives switch signals from Trigger, Cold Feed, Gas Purge, Trigger
TACH Interlock
FILTER
FREQUENCY = SPEED 5V = OFF 200 ohm • Reads WFS potentiometer.
LED • Communicates with optional timer kit to control burnback, postflow.
0V = MIN SPEED WIRE
FEED
LOW = DISABLE • Controls motor speed with PWM.
5V = MAX SPEED HIGH = ENABLE
SPEED COLD • Turns Gas Solenoid on, off.
FEED
• Reads the motor tachometer.
200 ohm
• Monitors motor current, lights yellow thermal LED if over 3.75 amps for an
SOLENOID LOW = DISABLE
FET
GAS
SOLENOID
GAS HIGH = ENABLE extended time period. LED remains lit for 30 – 60 seconds to allow motor
0.25
PURGE to cool.
10K ohm • Does NOT support Run-in at this time.
ohm
LOW = DISABLE • Operates on 24-42 VAC. Maximum WFS and/or maximum pull force may
INTERLOCK be less when operating at 24 VAC.
• Does NOT operate on 115 VAC.
SCHEMATIC = G4559
LF-72/74

SCHEMATIC - COMMON ANALOG CONTROL PC BOARD - (G4559 SHEET 1)
LF-72/74

LF-72/74

LF-72/74

PC BOARD ASSEMBLY - COMMON ANALOG CONTROL - (G4560-2E0)
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
LF-72/74

SVM171-A: Service Manual

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Safety Depends on You

Lincoln arc welding and cutting

Copyright © 2007 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

CALIFORNIA PROPOSITION 65 WARNINGS

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

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• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

sure level should be checked upon installation and periodi-

5.e. Read and understand the manufacturer’s instructions for this

5.f. Also see item 1.b.

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2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

5. Toujours porter des lunettes de sécurité dans la zone de

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Installation LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Installation LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section AA

Operation LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Operation LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BB

Accessories LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

Accessories LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section CC

Maintenance LF-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Maintenance LF-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DD

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P501 Series (LF-72)

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Procedure for Changing Drive and Idle Roll Sets ......................................................A-11

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TECHNICAL SPECIFICATIONS: LF-72 Wire Feeder

SPEC.# TYPE WIRE FEED SPEED RANGE

K2327-1 Base Model

( 282 mm) (259 mm) (328 mm)

WELDING CAPACITY RATING

Amp Rating Duty Cycle

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SAFETY PRECAUTION MOUNTING

• Do not touch electrically hot parts.

The LF-72 may be placed on a bench or mounted on

Place the LF-72 in a clean and dry location.

Do not stack the LF-72.

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BENCH MOUNT BOOM MOUNT

Swivel Kit and Bench Model, Standard Duty

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ELECTRIC SHOCK can kill.

• Turn off the input power to the

• Do not touch electrically hot parts.

WELD CABLE SIZES

Table A.1 has the copper cable sizes recommended for

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

325 100 2/0 2/0 2/0 2/0 3/0

500 60 2/0 2/0 3/0 3/0 4/0

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COAXIAL WELD CABLES A coaxial weld cable is constructed by 8 small leads

wrapped around one large lead. The large inner lead