Lincoln Electric LN-742 LN-742 manual

LN- 742 & LN- 742H W ire Feeders OPERA TOR’S MANUAL IM476-A August, 2005 Safety Depends on You 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 thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT W[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS LN-742 & LN-742H Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications - LN-742 . . . . . . . . . [...]

A-1 INST ALLA TION A-1 PHYSICAL DIMENSIONS ENVIRONMENT AL RA TING (ALL MODELS) BOTH LN-742 AND LN-742H LENGTH TOTAL WEIGHT LESS ELECTRODE 24 lbs (11.0 kg) WIDTH HEIGHT 2 ROLL FEEDER WITH WIRE STAND (K377) 2 ROLL FEEDER WITHOUT WIRE STAND 4 ROLL FEEDER WITH WIRE STAND (K377) 4 ROLL FEEDER WITHOUT WIRE STAND 34 lbs (15.5 kg) 28.7 lbs (13.1 kg) 38.7 l[...]

A-2 INST ALLA TION LN-742 & LN-742H A-2 MOUNTING LOCA TION The LN-742 wire feeders can be mounted directly on top of the power source providing that it is secure and level. The LN-742 can also be mounted to an undercarriage when portability is required. The LN-742 should be installed upright on a horizontal surface. A K178-1 mounting platform i[...]

A-3 INST ALLA TION LN-742 & LN-742H A-3 4. Connect the remaining end of the control cable with the eight-socket cable plug to the mating receptacle on the LN-742. 5. Referring to Figure A.2, install the input cable under the wire reel mounting stand strain relief clamp. Remove the screws holding the clamp to the base of wire reel mounting assem[...]

A-4 INST ALLA TION LN-742 & LN-742H A-4 ELECTRIC SHOCK CAN KILL TURN INPUT POWER OFF BEFORE CONNECTING THE LN-742 WIRE FEEDER. WARNING CLEVELAND, OHIO U.S.A - + LINCOLN POWER SOURCE LN-742 WIRE FEEDER LN-742 INPUT CABLE ASSEMBLY TO WORK ELECTRODE CABLE 14-SOCKET BOX RECEPTACLE, FRONT VIEW AND 14-PIN CABLE PLUG, REAR VIEW FUNCTIONS ARE LISTED FO[...]

A-5 INST ALLA TION LN-742 & LN-742H A-5 WORK CABLE Connect a work lead of sufficient size and length (Table A.1) between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. TABLE A.1 – WORK LEAD SPECIFICATIONS Copper Work Cable Size, AWG Current 60% Up To 5[...]

A-6 INST ALLA TION LN-742 & LN-742H A-6 W A TER CONNECTIONS (FOR W A TER COOLED GUNS) The LN-742 must have a K590-1 Water Solenoid Kit installed (see Section C, Accessories ). Refer to Figure A.5 and perform the following steps: The maximum water pressure permitted for use with the LN-742 is 55 psi (3.8 bar). NOTE: If not using a Lincoln water [...]

A-7 INST ALLA TION LN-742 & LN-742H A-7 GMA W SHIELDING GAS HOOKUP Gas under pressure is explosive. Always keep gas cylinders in an upright position and chained to the undercarriage or a stationary support. See American National Standard Z-49.1, “ Safety In Welding And Cutting ” , published by the American Welding Society. -----------------[...]

B-1 OPERA TION LN-742 & LN-742H B-1 OPERA TING INSTRUCTIONS Read and understand the entire Operation Section prior to operating the machine. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work or ground. • Always wear dry insulating gloves[...]

B-2 OPERA TION B-2 • 0.045 to 5/64 in. (1.2 to 2.0 mm) cored wire for Innershield processes. The LN-742H is capable of the following wire feed ranges: • 0.025 to 0.045 in. (0.6 to 1.2 mm) solid wire for gas- metal-arc or CV submerged arc processes. • 0.035 to 0.045 in. (1.2 mm) cored wire for Outershield, Metalshield or Innershield processes.[...]

B-3 OPERA TION B-3 FUNCTION SELECTION CONTROLS. This control enables the operator to select the function that will be displayed as shown by the indicator lights. Pressing the key causes the mode lights to sequence (from top to bottom). Settings displayed in the LED display are adjusted using the setting adjustment arrows to the left of the LED disp[...]

B-4 OPERA TION B-4 LN-742 & LN-742H GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE LARGE RADIUS DRIVE ROLL INCOMING GUIDE TUBE SMALL RADIUS IDLE ROLL CLAMPING COLLAR SPACER (IF REQUIRED) OUTPUT SHAFT DRIVE ROLL HALVES FIGURE B.2 – INSTALLING DRIVE ROLLS ON A TWO-ROLL FEEDER.[...]

B-5 OPERA TION B-5 3. Remove the hex head screw and clamping collar. Remove the drive roll from the shaft. 4. The new roll to be installed is stamped for the size wire to be fed. An “ A ” after the size indicates aluminum wire. Remove the rolls from the kit and wipe them clean. Wipe the output shaft and locating shoulder clean. 5. Use the clamp[...]

B-6 OPERA TION B-6 LN-742 & LN-742H FIGURE B.3 – INSTALLING DRIVE ROLLS ON A FOUR-ROLL FEEDER. GUIDE TUBE DETAIL OUTGOING GUIDE TUBE INSERT OUTGOING GUIDE TUBE MIDDLE GUIDE TUBE SMALL RADIUS IDLE ROLL LARGE RADIUS CLAMPING COLLAR OUTPUT SHAFT SPACER (IF REQUIRED) DRIVE ROLL HALVES[...]

B-7 OPERA TION B-7 IDLE ROLL PRESSURE SETTING The idle roll pressure is set at the factory. Two-roll feeders are set with the pressure adjustment knob backed out two turns from full pressure, and four-roll feeders are set backed out three turns. This is an approximate setting. For small wire sizes and aluminum wire the optimum idle roll pressure va[...]

B-8 OPERA TION B-8 WIRE LOADING Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel Package Using the Molded Plastic K363-P Readi-Reel Adapter: The Spindle should be located in the LOWER mounting hole of the K1524-1 Universal Stand if used. 1) Depress the Release Bar on the Retaining Collar and remove it from the spindle. NOTE: Earlier spindles used a [...]

B-9 OPERA TION B-9 TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS (12 in./300 mm DIAMETER) OR 13-14 lb (6 kg) INNERSHIELD COILS: The spindle should be located in the lower mounting hole of the K1524-1 Universal Stand if used. [For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto the spindle.] [For 13 to 14 lb (6 kg) Innershield [...]

B-10 OPERA TION B-10 WIRE REEL LOADING – 50 AND 60 LB COILS (K303 OR K376 WIRE REEL ST AND) ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrode coils includes a two-position brake assembly. Generally the brake should be at the inner position (nearest to the wire reel shaft) for wire feed speeds below 400 in./min (10 m/min)[...]

B-11 OPERA TION B-11 WIRE REEL LOADING – 50 AND 60 LB COILS (K1524-1 UNIVERSAL WIRE REEL ST AND) TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL: (USING K1504-1 COIL REEL) (FOR 50 to 60 lb READI-REELS A K438 READI-REEL ADAPTER MUST BE USED.) The spindle should be located in the UPPER mount- ing hole. 1. With the K-1504-1 Coil Reel mounted on the 2 [...]

B-12 OPERA TION B-12 MAKING A WELD 1. Use only constant voltage power type sources. If using a multiple process power source, be sure it is set for constant voltage output per instructions in the manual for the power source. 2. Set the power source polarity switch or properly connect the electrodes and work leads for the correct electrode polarity.[...]

C-1 ACCESSORIES C-1 GENERAL The following is a list of the accessories that can be used with the LN-742 wire feeder. A detailed description of each item is given later in this section. LN-742 & LN-742H Product Number Name K163 Undercarriage K178-1 Mounting Platform K589-1 Remote Control Kit K590-1 Water Solenoid Kit K590-2 Water Connection Kit [...]

C-2 ACCESSORIES C-2 K163 UNDERCARRIAGE The undercarriage includes casters, wheels, a handle, and related hardware. Casters are mounted at the front and wheels at the rear of the platform. The handle is bolted to the front of the platform so the wire feeder can be tilted back and wheeled like a two-wheel truck. Installation sheet M13424 is provided [...]

C-3 ACCESSORIES C-3 K320 FLUX T ANK Either turn off the incoming air line or remove the quick disconnect if one has been installed. Slightly loosen the tank cap and let the air in the tank escape in the holes in the side of the cap. After pressure has been released, remove the cap from the tank. Using the funnel provided, put 100 pounds of flux in [...]

C-4 ACCESSORIES C-4 SUBMERGED ARC GUNS The K112 gun and cable assembly is recommended for welding with 1/16 in. solid steel electrode at up to 500 amps. Gun cable length is 15 feet. GMA W GUNS An expanding line of Magnum GMA gun and cable assemblies are available to allow welding with solid and cored electrodes using the GMAW process. See the appro[...]

C-5 ACCESSORIES C-5 K377 SMALL MOUNTING ST AND FOR READI-REEL COILS AND 22 TO 30 LB SPINDLE WITH 2 IN. I.D. This assembly includes a wire reel spindle (similar to the K162 spindle) attached to a small frame. The unit is supplied with the K363 Readi-Reel Adapter for using the Lincoln “ Readi-Reel Electrode Coils ” . Without the adapter the unit [...]

C-6 ACCESSORIES C-6 DRIVE ROLL KITS Table C-2 lists the appropriate drive roll kits for each type of wire used. LN-742 & LN-742H 2-Roll 4-Roll Steel Wire Sizes 0.068-3/32 in. (1.7-2.4 mm) Cored KP653-3/32C KP655-3/32C 1/16 in. (1.6 mm) Cored or Solid KP653-1/16 KP655-1/16 0.045-0.052 in. (1.2-1.3 mm) Solid KP653-052S KP655-052S 0.045-0.052 in. [...]

D-1 MAINTENANCE D-1 LN-742 & LN-742H ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUBES After feeding every coil of wire, inspect the drive roll section. Clean the assembly as necessary. Do not use solvent to clean the drive roll assembly as it may wash the lubricant out of the bearings. The drive rolls and guide tubes are stamped with the wire si[...]

E-1 TROUBLESHOOTING E-1 LN-742 & LN-742H If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION W ARNING ELECTRIC SHOCK can kill. • Do not touch electrically [...]

E-2 TROUBLESHOOTING E-2 LN-742 & LN-742H Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PR[...]

E-3 TROUBLESHOOTING E-3 LN-742 & LN-742H Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PR[...]

E-4 TROUBLESHOOTING E-4 LN-742 & LN-742H Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PR[...]

E-5 TROUBLESHOOTING E-5 LN-742 & LN-742H Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PR[...]

E-6 TROUBLESHOOTING E-6 LN-742 & LN-742H Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PR[...]

E-7 TROUBLESHOOTING E-7 LN-742 & LN-742H Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PR[...]

F-1 DIAGRAMS F-1 LN-742 & LN-742H NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment cod[...]

NOTES LN-742 & LN-742H[...]

NOTES LN-742 & LN-742H[...]

F-4 NOTES LN-742 & LN-742H F-4[...]

F-5 NOTES LN-742 & LN-742H F-5[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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