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Lincoln LN-742H Welder User Manual

1. Electrical 2 Parts Manual LN 742 amp LN 742H LINCOLN 8 Page i iv Section A A 1 A 2 A 2 A 5 A 5 A 5 A 6 A 7 Section B B 1 B 1 B 1 B 1 B 2 B 3 B 3 B 3 B 3 B 7 B 8 B 12 B 12 Section C C 1 C 2 C 3 C 3 C 4 C 5 C 6 Section D D 1 D 1 Section E E 1 E 2 Section F P 228 vi 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS LN 742 INPUT VOLTAGE 40 to 42V 10 50 60 Hz 4 0 Amps WIRE FEED SPEED SYSTEM WIRE SPEED RANGE LN 742 50 in to 770 in per minute 1 25 to 19 5 m min LN 742H 80 in to 1200 in per minute 2 00 to 30 5 m min WIRE DIAMETERS SYSTEM ELECTRODE DIAMETER LN 742 SOLID 0 025 in through 1 16 in 0 6 through 1 6 mm LN 742H SOLID 0 025 in through 0 045 in 0 6 through 1 2 mm LN 742 0 045 in through 3 32 in 1 2 through 2 4 mm LN 742H 0 035 in 0 9 mm TEMPERATURE RATING ALL MODELS OPERATING 4 F to 104 F 20 C to 40 C STORAGE 40 F to 104 F 40 C to 40 C PHYSICAL DIMENSIONS TOTAL WEIGHT BOTH LN 742 AND LN 742H LENGTH WIDTH HEIGHT LESS ELECTRODE 2 ROLL FEEDER 9 62 in 9 76 in 10 89 in 24 Ibs WITHOUT WIRE STAND 244 mm 247 mm 277 mm 11 0 kg 2 ROLL FEEDER 20 68 in 9 76 in 17 00 in 34 Ibs WITH WIRE STAND K377 525 mm 247mm 432 15 5 kg 4 ROLL FEEDER 10 60 in 11 60 in 11 11 in
2. DIAGRAMS gut 9 aca i 7 ai x x amp At T 5 QvdA3M O D TIUIUUTUDTD V To op Lt de 11 PERRIER trd ot ie cin ULL QHVOS d i 8 5 itiit s 72 171 CONT OS Eo te FINIS ert TNC 140 ER 3 evo 3 ct1oz73 cVZ N1 LN 742 amp LN 742H LINCOLN E NOTES LN 742 amp LN 742H LINCOLN 8 NOTES LN 742 amp LN 742H LINCOLN 8 F 4 NOTES LN 742 amp LN 742H LINCOLN 8 F 4 F 5 NOTES LN 742 amp LN 742H LINCOLN 8 F 5 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem
3. leur place Mar 93 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You io take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registratio
4. 28 7 lbs WITHOUT WIRE STAND 269mm 295mm 282 mm 13 1 kg 4 ROLL FEEDER 21 66 in 11 60 in 17 00 in 38 7 lbs WITH WIRE STAND K377 550 mm 295 mm 432 mm 17 7 kg ENVIRONMENTAL RATING ALL MODELS IP21 IEC 529 LN 742 amp LN 742H LINCOLN A 2 INSTALLATION A 2 MOUNTING LOCATION 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 is available for mounting the LN 742 to the top of Idealarc power sources Refer to Section C Accessories for details INPUT CABLE CONNECTIONS Refer to Section C Accessories for descriptions of the various input cable assemblies available for the LN 742 wire feeder A WARNING Turn input power off before connecting the LN 742 wire feeder For connecting an LN 742 to a specific Lincoln power source follow steps 1 through 5 and refer to the connection diagram in Figure A 3 The welding cable used must be sized according to the current and the duty cycle of the application With input power disconnected at the source install the input cable per connection diagram A 3 and complete the following instructions 1 Connect the end of the control cable with the 14 pin cable plug to the mating receptacle on the power source 2 C
5. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oyli
6. o opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas XYVTFFYA H ERZKRU D PRE EFERII FE e SAUTER Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas L EUITTF amp L SER HGTBI BUSUR RE SERB e 430 wel Me z WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ie BIR Chinese oe lue chal TAU Gall d Aach arin Mall oe us Aie by pha NM Jl ale AREY cuts UI ai Jada Y e Aale Cut Al dl LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR SBM OBUOX D OHBRBEE lt K EFTBRMLTKEW CL TRHOKRERE HS TFU HAM Rr de D RES AMEN RAB 0 Al Soll AIXAM SALAD HAY zeit TAS PSP HHCH alal dl Gud al ply Gail
7. A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te a l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU EUR Ea fE za SH7IAE else e 8xbiogst SUAS MAS AH PARAH 587E MBH Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N
8. Equipment Controls and Settings Acceleration Setting English or Metric Speed Display Units Circuit Protection Drive Roll Installation Idle Roll Pressure Setting Wire Loading 2 EINEN us e oe a Making Weld Wire Reel Changing ACCeSSOrIGS Se A Se a ee ee Generals heehee EE Flux System Components Power Input Cables Welding et tpm Spindles Stands and Adapters Attaching the Wire Reel Stand Drive Roll deed ee eer eee Maintenance INN UNE NN m no ave onu aie muse wae eee ete Routine Maintenance Periodic Maintenance Troubleshooting and Repair How To Use Troubleshooting Guide Troubleshooting Guide
9. 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 It should be at the outer position for the faster wire speeds often used when feeding smaller diameter electrode To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit TO MOUNT A 50 OR 60 LB COIL 1 To remove the wire reel from its shaft grasp the spring loaded knob and pull out This straightens the knob so it seats into the shaft when released Remove the reel 2 Lay the reel flat on the floor Loosen the spinner nut and remove the cover plate See Figure B 6 3 Place the coil of electrode on the reel so it unwinds as the reel rotates clockwise DO NOT cut the tie wires at this time 4 Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires 5 When loading 0 030 to 0 045 electrode be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil sides needed for trouble free wire feeding 6 Put the cover plate on the reel so the four arms of the cover plate straddle and are in line with the spring loaded arms of the reel 7 Tighten the cover as
10. M13424 is provided with the undercarriage K178 1 MOUNTING PLATFORM This is a turntable type platform for mounting the LN 742 to the top of Idealarc power sources Bolt the platform to the lift bail per the instructions M16260 supplied with the platform K589 1 REMOTE CONTROL KIT Provides remote potentiometer control of weld speed and arc voltage up to 16 4 ft 5 0 m from the wire feeder Power source must have remote control capability K856 Power Source Remote Kit required for 300 400 and smaller CV Model machines below Code 9900 Install K589 1 Kit per S20520 installation instructions provided with the kit K590 1 WATER SOLENOID KIT Includes a solenoid valve already attached to a mounting bracket and supply connection manifold assembly for easy installation on the upper rear panel of the LN 742 case Also includes water cooled gun tube fittings and self sealing outlet and inlet quick connectors for mounting to the front of the LN 742 case K590 2 WATER CONNECTION KIT This kit is the same as the K590 1 except that it does not include the solenoid for water coolers requiring continuous flow K857 REMOTE VOLTAGE CONTROL KIT Installs on the side of the LN 742 control box cover and gives voltage control at the wire feeder K857 can be installed on the LN 742 when it is used with newer Lincoln power sources that are equipped with a 6 socket ms type receptacle or K864 14 pin connector adapter for connect
11. for technical troubleshooting assistance before you proceed LN 742 amp LN 742H LINCOLN 8 Jequunu epoo eu 104 0 eidelt si au sjeued y euo uo y LL peised si epoo sejnomed eut siy Aq 10 eq jou 1 AJUO 104 SI SIUL LON vole 96 626 De OR e 9 2 Ge etc aa i vore FO OFNNO0 10 5 NON d d Me TES e EM t gt gt e 11 XIE Li 5 ZCNZACZS ON ETANICN ER LCTO dO esst 3 KGE EL DI p LOLOANNCD uu 5 lt 76 6 ELEM 915 d kaa CUBRE 4 RE NOV BOX ES eg N COD 0 0207 1 2 J DE Ia SOVITOA STACON 427 N7 34 NO AINC VN 7C S CAYO re 10725 _NzNOANOS 104 SLIDE FONE CES OMEZANNN Nd y y JONINOTS N AIENIN ALI V2 SN See 109 2 die SICA AS VOIE LOS TA SE YOHO w qavo ti 95 2 tr NIS 9 d IOHLNOO eur pete zy iS 7 310v lt 21479 Inc
12. into the drive roll WARNIN 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle NOTE Earlier spindles used a threaded collar See Figure B 5a or e ELECTRIC SHOCK B 5b 2 Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the backside of the spool Be certain the wire comes off the reel in a direction so as to de reel from the bottom of the coil 3 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle 5 ELECTRODE FEEDING AND BRAKE ADJUSTMENT 6 1 Turn the Readi Reel or spool until the free end of the electrode is accessible can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain hot for several seconds after the gun trigger is released Inch the electrode through the gun Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Do not overtighten LN 742 amp LN 742H LINCOLN P B 10 WIRE REEL LOADING 50 AND 60 LB COILS K303 OR K376 WIRE REEL STAND ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrode coils includes a two position brake assembly
13. is very important that reclaimed flux to be used in the continuous flux feeding system be passed through the K310 screen or its equivalent LN 742 amp LN 742H LINCOLN 8 ACCESSORIES K320 FLUX TANK 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 the tank It is very important that only new or properly reclaimed flux be put in the tank Coarse particles and or magnetic particles will stop the flux feeding process New Lincoln flux is properly screened at the factory All reclaimed flux must be separately screened through a vibrating screen with 0 065 in to 0 075 in openings and be put through a magnetic separator The K310 vibrated screen and K58 magnetic separator are available for this purpose The screen in the funnel supplied with the tank has much larger openings and its only purpose is to keep paper and slag out of the tank There will always be a small amount of air and possible drops of water coming out of the end of the tube coiled under the tank This is an automatic disposal system in case the plant air has water and dirt in it POWER INPUT CABLES A variety of power input cable assemblies are avail able for various current ratings and power sourc
14. it unwinds from the bottom as the reel rotates 3 Tighten the spinner nut against the reel cover as much as possible by hand using the reel cover spokes for leverage DO NOT hammer on the spinner nut arms 4 Cut and remove only the tie wire holding the free end of the coil Hook the free end around the rim of the reel cover and wrap it around to secure Cut and remove the retaining tie wires OPERATION FIGURE B 7 K1504 1 COIL REEL SPINNER NUT COVER PLATE ANSE CARDBOARD AFS COIL LINER COIL 2 WIRE SPRING LOADED ARM CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in backlash of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded 5 Be sure the coil is engaged with the spindle brake pin and the Release Bar and Retaining Collar pops up and that the collar retainers fully engage the retaining groove on the spindle LN 742 amp LN 742H LINCOLN B 12 OPERATION B 12 MAKING A WELD 9 Position the electrode over the joint The end of the electrode may be lightly touching the work Use only constant voltage power type sources If using a multiple process power source be sure it 10 1 1 is set for constant voltage output per instructions e des 2 give
15. or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS 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 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and
16. solid state overload protection of the wire drive motor If the wire drive motor becomes overloaded for an extended period of time the protection circuitry turns off the power source wire feeder and solenoid then displays the error code E30 on the LED display This indicates the wire drive motor is overloaded with the number indicating the time remaining in seconds before the unit will automatically reset This number continues to decrement every second until it reaches zero At that time the unit resets automatically and the previous display will return indicating that the unit is ready for operation Over loads can result from improper tip size liner drive rolls or guide tubes obstructions or bends in the gun cable feeding wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding DRIVE ROLL INSTALLATION CHANGING DRIVE ROLLS FOR TWO ROLL WIRE FEEDERS To change drive rolls on a two roll wire feeder refer to Figure B 2 and perform the following steps 1 Turn off the welding power source 2 Rotate the latch knob on the quick release arm LN 742 amp LN 742H LINCOLN B4 OPERATION FIGURE 2 INSTALLING DRIVE ROLLS ON TWO ROLL FEEDER E CLAMPING 4 COLLAR SPACER IF REQUIRED DRIVE ROLL HALVES K OUTPUT Lk SHAFT ai 27 le GUIDE TUBE DETAIL LARGE RAD
17. 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 LN 742 amp LN 742H LINCOLN 8 E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual The welding arc is variable or 1 Check the welding cables for hunting loose or faulty connections Make sure the wire feed speed voltage polarity and shielding gas are correct for the process being used Check for mechanical restric tions in the wire feed path Make sure the welding power source is functioning properly If all recommended possible areas of misadjustment have been checked Poor arc striking with sticking or 1 Make sure the wire feed speed and the problem persists Contact blast offs The weld bead may be voltage polarity and shielding Your local Lincoln Authorized ropy and narrow gas are correct for the process Field Service Facility being used Make sure the welding power source is functioning properly Make certain the gas solenoid is operating properly and the gas flow rate is correct for the pro cedure The welding gun may be faulty Check for gas leaks or replace gun CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility
18. that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 3 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 6 5 LINCOLN Shielding gases used for arc welding can displace air cause injury or death Always use enough ventilation especially in confined areas to insure breat
19. 00 85 mm 500 Amps 00 67 mm 000 85 mm 600 Amps 000 85 mm 0000 107 mm GUN AND CABLE ASSEMBLIES The LN 742 can be used with several guns In most cases Lincoln guns and cables are shipped assembled ready to weld Use the gun and cable assembly for the electrode type solid Outershield or Innershield and electrode size to be used Refer to Section C Accessories for different gun types GUN CABLE CONNECTIONS Lay the cable out straight Insert the connector on the welding conductor cable through the large hole in the front panel of the LN 742 and into the brass conductor block on the front of the gearbox Refer to Figure A 4 Make sure it is all the way in and tighten the locking knob Keep this connection clean and bright Connect the control cable amphenol plug into the mating 5 cavity receptacle on the front of the control section below the keypad FIGURE 4 GUN CABLE CONNECTIONS AMPHENOL PLUG CONDUCTOR GUN CABLE BLOCK ASSEMBLY LN 742 amp LN 742H LINCOLN 8 A 6 INSTALLATION A 6 WATER CONNECTIONS FOR WATER 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 cooler and if your water cooling device is not designed for use with a waterline solenoid valve y
20. CABLE LN 742 amp LN 742H LINCOLN 8 A 4 INSTALLATION A 4 FIGURE LN 742 WIRE FEEDER TO LINCOLN POWER SOURCE CONNECTION DIAGRAM TURN INPUT POWER OFF BEFORE CONNECTING THE LN 742 WIRE FEEDER ELECTRIC SHOCK CAN KILL LINCOLN POWER SOURCE 14 PIN AMPHENOL LN 742 WIRE FEEDER TO WORK LN 742 ELECTRODE CABLE INPUT CABLE ASSEMBLY K 42 K 42 1 41 1 41 5 0 16 C 2 de l d H 21 H 21 o C 2 O D 4 e Ke G 75 asp 9 7 D 4 E 77 F 76 F 76 E 77 14 SOCKET BOX RECEPTACLE FRONT VIEW 14 SOCKET BOX RECEPTACLE REAR VIEW AND 14 PIN CABLE PLUG REAR VIEW AND 14 PIN CABLE PLUG FRONT VIEW PIN LEAD FUNCTION C 2 TRIGGER CIRCUIT D 4 TRIGGER CIRCUIT E 77 OUTPUT CONTROL F 76 OUTPUT CONTROL G H 75 OUTPUT CONTROL 21 WORK 41 42N AC K 42 42N AC FUNCTIONS ARE LISTED FOR REFERENCE ONLY AND EACH MAY OR MAY NOT BE PRESENT IN YOUR EQUIPMENT LINCOLN LN 742 amp LN 742H LINCOLN 8 5 INSTALLATION 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 AT WORK LEAD SPECIFICATIONS Copper Work Cable Size AWG Current 60 Up To 50 Ft 50 Ft 100 Ft Duty Cycle 15 2 m2 15 2 30 4 m 300 Amps 0 53 mm 00 67 mm 400 Amps 00 67 mm 0
21. Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra RABE ELE OMLMPT APSSAPREBS NTUSHILT FSU e E GUB AER GH Oa CRM ER ecu Xe uc a Sal HIE Weal AMI W uil el all Quali Y O 1 gl o as lala AA ll DA dan Y Jio wae Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos OA VE U DOMTORRIER THEW EKA eis Jo al gh Ad AIX ole Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo A HRUSHICRBRELTE EU OMAR RSR ez 119 Sal HEHA daig 4 Lilly gupay Daun READ AND UNDERSTAND THE MANUFACTURER 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA
22. F ACTION The LN 742 voltmeter does not function or read correctly when the actual arc voltage is present The wire feeder is feeding wire correct ly The LN 742 shuts down while welding and the HXX symbol appears on the display The display and or indicator lights do not change when the arrow or select keys are pressed The arrow keys do not change the welding wire feed speed 1 Make sure the polarity switch on the Lincoln welding power source is in the correct position for the welding process Check or replace the control cable Check the continuity zero ohms of leads 21 and 67 Check for mechanical restric tions in the wire feed path Make sure the control cable is connected to the welding power source correctly Check the 42 VAC fuse or cir cuit breaker in the welding power source If a remote control unit is con nected to the LN 742 the arrow keys will not change welding wire feed speed Use the WFS pot on the remote control unit or disconnect the remote control unit and use the arrow keys CAUTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 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 proc
23. IM476 A LN 742 amp LN 742H Wire Feeders For use with machines having Code Numbers 10027 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 WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL 10028 10048 10049 10238 10239 10240 10241 ISO 9001 r D ed and Mani ality Program lt gt ign Desig ui ANSI RAB Ba ae A nder by d and Manuf y LINCOLN Copyright O 2005 Lincoln Global Inc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS 1 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 rep
24. IUS UE DRIVE TUBE f dii OUTGOING GUIDE TUBE L HI A IDLE go INCOMING ROLL GUIDE SMALL TUBE RADIUS LN 742 amp LN 742H LINCOLN B 5 OPERATION Remove the hex head screw and clamping collar Remove the drive roll from the shaft 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 Use the clamping collar and hex head screw to install the roll on the output shaft Certain size drive rolls consist of two roll halves and may contain a spacer If the drive roll you are installing contains a spacer the spacer fits between the two halves of the drive roll Tighten the hex head screw Back out the guide tube clamping screws Remove the old guide tubes if installed Insert the longer guide tube into the rear hole and the other guide tube through the front hole The fine wire chisel point end of the guide tube must have the larger radius end next to the drive roll See Figure B 2 Push the guide tube back as far as it will go and tighten the clamping screw Insert the incoming guide tube as far back as it will go and tighten the clamping screw The clamping screws are dog points When the guide tubes are properly installed these dog points will lock into the annular grooves in each of the guide tubes Set the idle roll pressure as detailed
25. K1557 1 swivel platform 60 LB 27 2 KG COIL ADAPTER K1504 1 Permits 50 60 Ib 22 7 27 2 Kg coils to be mounted to a 2 51mm spindle K1551 1 INSULATED LIFT BALE Provides a bolt on lift bale with an electrically insulated lift hook K1556 1 CASTER KIT Comes with 4 light duty 2 O D casters which mount in place of the rubber feet on the wire stand Use in light duty applications where portability is required Can be used in combi nation with the K1557 1 swivel platform K1557 1 SWIVEL PLATFORM Allows for the mounting of the wire feeder reel stand assembly on top of a suitable power source if the need for the wire feeder reel stand assembly to swivel is desired Also has mounting holes in the base feet for mounting to any surface that it can be fastened to Comes with a rotating tool tray to hold gun tips guide tubes drive rolls etc Will work in combination with the K1556 1 caster kit LN 742 amp LN 742H LINCOLN 8 C5 ACCESSORIES 5 K377 SMALL MOUNTING STAND FOR READI REEL COILS AND 22 TO 30 LB SPINDLE WITH 2 IN LD 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 is capable of handling spools with a 2 in I D a 12 in maximum O D and a 4 in width For spools with an 8 in O D a K468 spindle adapter is ava
26. L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
27. The symbol should not reappear when power is returned Remove input power to the feeder 42 VAC Wait 5 sec onds The symbol should not reappear when power is returned CAUTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 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 LN 742 amp LN 742H LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual The wire is feeding rough or not feeding The drive rolls are turn ing The drive rolls do not turn when the gun trigger is pressed The gas solenoid activates and arc voltage is present 1 Check for mechanical restric tions in the wire feeding path Check the gun and gun compo nents Check the drive roll position and idle roll pressure The electrode may be dirty or rusty Check for the correct gun liner tip and guide tubes Check plug J5 on the control board for loose or faulty con nections CAUTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the
28. a 14 pin connector receptacle such as the Invertec V300 PRO V350 PRO DC 400 DC 600 DC 655 DC 650 PRO or Lincoln CV type power sources The LN 742 is capable of the following wire feed ranges e 0 025 to 1 16 in 0 6 to 1 6 mm solid wire for gas metal arc or CV submerged arc processes 0 045 to 3 32 in 1 2 to 2 4 mm cored wire for Outershield gas metal arc processes LN 742 amp LN 742H LINCOLN 8 B 2 OPERATION B 2 0 045 to 5 64 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 CONTROLS AND SETTINGS The operator controls are located on the keypad shown in Figure B 1 The keypad consists of 7 membrane keys with tactile feel embossed domes that are generously spaced to provide easy selection even while wearing welding gloves a long life 3 1 2 digit 7 segment LED display with 0 56 in 14 2 mm character height permitting easy viewing even from long gun cable distances and high intensity red LED indicator lights that allow for viewing at almost any angle TRIGGER MODE CONTROLS This control enables the operator to choose the mode of operation as shown by the indicator lights Pressing the key causes the mode lights to sequence from t
29. all the way onto the adapter until the retaining spring pops up fully A WARNING Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi Reel Cage in place Retaining Spring must rest on the cage not the welding elec trode 9 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle FIGURE B 5b Retaining Collar 2 IN SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR GROOVES READIREEL INSIDE CAGE WIRES RELEASE BAR LN 742 amp LN 742H LINCOLN P B 9 OPERATION B 9 TO MOUNT 10 TO 44 Ib 4 5 to 20 kg SPOOLS 2 12 in 300 mm DIAMETER OR 13 14 Ib 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 Ib 6 kg Innershield coils a K435 Coil Adapter must be used While tightly holding the electrode cut off the bent end and straighten the first six inches Cut off the first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing birdnest Insert the free end through the incoming guide tube Press the cold inch key or gun trigger and push the electrode
30. dy equipped with optional dust shield S14543 K468 SPINDLE ADAPTER FOR 8 IN O D SPOOLS Permits 8 in 208 mm O D spools to be mounted on 2 in 51 mm O D spindles For K377 and K445 or K303 and K376 with optional K162H adapter M11514 WIRE REEL DUST SHIELD DOOR FOR K303 AND K376 In extremely dusty and dirty locations this door kit can be added to those units having the dust shield kit 814543 This door kit includes a hinged door and sliding bottom seal When these parts are attached to the reel support per the instructions included the unit becomes a completely enclosed housing Order part no M11514 14543 WIRE REEL DUST SHIELD FOR K376 50 TO 60 LB WIRE REEL MOUNTING STAND A shield is available to cover the wire and reel to protect the wire from falling dirt and dust Order part no 514543 Instructions are provided with the kit ATTACHING THE WIRE REEL STAND The mounting hardware for mounting the stands is included with the LN 742 Screws and washers are inserted in their respective mounting holes To connect 1 Remove the three 3 8 in hex head bolts from the back of the wire feed unit 2 Place the wire reel mounting stand mounting bracket in position against the back of the wire feed unit 3 Replace and tighten the hex head bolts The long screw and plain washer go into the top hole LN 742 amp LN 742H LINCOLN 8 C 6 DRIVE ROLL KITS ACCESSORIES Table C 2 lists the appropriate drive
31. e both idle rolls before welding For most applications best wire feeding will occur when both idle roll pressures are set the same FIGURE B 4 IDLE ROLL PRESSURE SETTING PRESSURE ADJUSTMENT KNOB LN 742 amp LN 742H LINCOLN P 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 threaded collar See Figure B 5a or B 5b 2 Place the Adapter on the spindle 3 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle 4 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 5 Position the Readi Reel so that it will rotate in a direction when feeding so as to be de reeled from the bottom of the coil FIGURE B 5a Threaded Locking Collar 2 IN O D SPINDLE ADAPTER GROOVES READI REEL INSIDE CAGE WIRES THREADED LOCKING COLLAR OPERATION B 8 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 7 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 8 Slide the cage
32. e con nection types All provide a polarized control cable plug and a lugged electrode cable for connection to the wire feeder K1819 CONTROL CABLES These control cables connect the wire feeder to the power source The wire feeder end is 8 anphe nol and the power source end is a 14 pin amphenol The control cable supplies 42VAC from the welding power source to the feeder It also carries a lead for the work voltage and sends signals for the gun trigger and remote voltage potentiometer See connection diagram of wire feeder to power source in the Installation Section K1817 CONTROL CABLE EXTENSIONS The control cable extensions are used to lengthen the control cable The extensions have a 14 pin amphenol on one end that connects to the K1819 cable and the other end has a 14 pin amphenol that connects to the welding power source Do not exceed more than 100 Ft 31m of total control length See connec tion diagram of wire feeder to power source in the Installation Section WELDING GUNS Welding guns can be broken down into groups according to the type of welding that is to be accomplished Select the appropriate welding gun from the following weld type groups INNERSHIELD GUNS K122 This submerged arc gun and its cable assem blies are rated 500 amps 60 duty cycle K115 This Innershield gun and its cable assemblies are rated at 450 amps 60 duty cycle Maximum wire size for LN 742 mode
33. e is being displayed in seconds FIGURE B 1 WIRE FEEDER CONTROLS COLD d G COLD INCH GAS PURGE sme ADJUSTMENT ARROW KEYS V TRIGGER MODE 40 TRIGGER SPOT agas Q O ood SE MODE CONTROLS Mammen Wocrveren DISPLAY O oop FUNCTION SELECTION CONTROLS E De TIMER LOCK d BURNBACK SELECTION GAS PURGE LED CONTROLS LN 742 amp LN 742H LINCOLN B 3 OPERATION 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 display The top light indicates the arc voltage is being displayed in volts The middle light indicates the inch speed is being displayed The bottom light indicates the weld feed speed WFS is being displayed INCREASE ARROW This key increases the setting of the parameter selected to be displayed using the Quick Set feature for fast and accurate setting DECREASE ARROW This key decreases the setting of the parameter selected to be displayed using the Quick Set feature for fast and accurate setting QUICK SET FEATURE This feature permits the arrow keys to control each display digit one at a time The d
34. eed LN 742 amp LN 742H LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual The purge key does not activate the gas solenoid The solenoid does activate when the gun trigger is pulled The gas solenoid does not activate either when the purge key is pressed or when the gun trigger is pulled The cold inch key does not activate the wire feed motor The wire feed motor operates normally when the gun trigger is pulled The HI symbol appears on the dis play when the voltmeter function is selected The Er symbol appears on the dis play The EXX appears on the display XX is some number from 1 to 10 The EP symbol appears on the display The uP symbol appears on the dis play Microprocessor RAM error 1 Contact your local Lincoln Authorized Field Service Facility Check plug J6 located on the control board for loose or faulty connections Contact your local Lincoln Authorized Field Service Facility If the arc voltage is greater than 44 VDC this is a normal condi tion The voltmeter only reads 0 44 VDC This is an EPROM error The parameter recalled at power up is out of range Press any key to reset unit Check all weld settings before proceeding with weld Remove input power to the feeder 42 VAC Wait 5 sec onds The symbol should not reappear when power is returned Remove input power to the feeder 42 VAC Wait 5 sec onds
35. enoid does not function No arc voltage present The display board indicates the LN 742 has input power applied Make sure the control cable is connected to the welding power source correctly Make sure the welding power source is turned on and func tioning properly Check the 42 VAC fuse or cir cuit breaker in the welding power source Check or replace the gun trigger switch Check the gun trigger recepta cle Check for loose or faulty connections CAUTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 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 LN 742 amp LN 742H LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION When the gun trigger is activated 1 Make sure the welding power the wire feed motor runs and the source is functioning properly solenoid functions but no arc volt Disconnect the control cable age is present from the Lincoln power source Place a jumper across sockets C and D of the 14 pin amphenol plug at the power source Open circuit voltage should be pre
36. hing air is safe 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 Also see item 1 b Mar 95 SAFETY WELDING SPARKS lt gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase
37. ilable The spindle has an adjustable braking system See Attaching the Wire Reel Stand procedure at the end of this section for installation procedures K378 SMALL MOUNTING STAND FOR 13 TO 14 LB INNERSHIELD COILS This assembly includes the same smaller frame as used in the K377 and the fully enclosed canister system for dereeling of the 14 Ib coil This system has a fixed brake for the 14 Ib coil See Attaching the Wire Reel Stand Procedure at the end of this section for installation procedures K435 SPINDLE ADAPTER FOR 14 LB COILS Permits 14 Ib 6 kg Innershield coils to be mounted on 2 in 51 mm O D spindles For K377 and K445 or K303 and K376 with optional K162H adapter K438 50 TO 60 LB READI REEL ADAPTER Adapts Lincoln Readi Reel coils of 50 to 60 Ib 22 7 to 27 7 kg to a 2 in 51 mm spindle Included with K445 K445 MOUNTING STAND FOR READI REEL COILS AND 50 TO 60 LB SPINDLE WITH 2 IN O D 50 to 60 Ib 22 7 to 27 7 kg Readi Reel mounting stand This assembly includes framework that a 2 in 51 mm O D spindle with adjustable brake and 50 to 60 Ib 22 7 to 27 7 kg K438 Readi Reel adapter Includes a lift bail and cable clamp for fastening the input cable assembly Does not include a dust shield A dust shield that covers the wire reel and protects the wire from falling dirt and dust is available for this unit Order part number 514543 This unit will accept the M11514 door kit see K303 but only if alrea
38. in the Idle Roll Pressure Setting procedure detailed later in this section CHANGING DRIVE ROLLS FOR FOUR ROLL WIRE FEEDERS To change drive rolls on a four roll wire feeder refer to Figure B 3 and perform the following steps 1 2 Turn off welding power source Remove the gun and cable from the conductor block on the feeder by loosening the hand screw and pulling the gun straight out of the block Open both quick release levers by moving the levers outward and pulling them toward you B 5 Loosen the thumb screws holding the guide tubes in place Remove the incoming and outgoing guide tubes if installed Remove the hex head screws and clamping collars from the output shafts Remove the drive rolls and middle guide tube The new rolls to be installed are stenciled with the wire size that will be fed An A after the number indicates aluminum wire Remove the rolls from the kit and wipe them clean Wipe the output shafts and locating shoulders clean Install one roll onto the output shaft closest to the incoming side of the feeder clamping collar and hex head screw Certain size drive rolls consist of two roll halves and may contain a spacer If the drive roll you are installing contains a spacer the spacer fits between the two halves of the drive roll Tighten the hex head screw Install the middle guide tube but do not tighten at this time When installing a 0 035 middle guide tube the larger radius
39. ion of the plug on the 28 ft 8 5 m control cable of the K857 See the instructions S19103 included with the kit FLUX SYSTEM COMPONENTS The flux system is available to permit the LN 742 to be used for submerged arc welding It is comprised of the components described below K58 MAGNETIC SEPARATOR The K58 is a permanent magnet type separator designed to fit the top of the standard fill funnel of the continuous flux feeding system The purpose of the separator is to remove magnetic materials such as mill scale and any other extraneous magnetic materials which may have been recovered along with the flux to be processed It is important to remove these magnetic particles from the flux which is to be used in the continuous flux feeding systems If the magnetic material is not removed it will gather around the nozzle of the gun and impede or shut off the flux flow when making relatively long welds or welding continuously The magnetic particles can also cause porosity in the weld K310 FLUX SCREEN The unit was designed to fit the top of either the standard fill funnel or a K58 magnetic separator The unit has a steel screen with 0 065 to 0 075 in openings and an air vibrator attached to the frame The vibrator can be used with air line pressures ranging from 20 through 100 psi For ease of handling the user should connect the incoming air line to the 1 8 in pipe elbow with the aid of a quick disconnect type air coupling It
40. is enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants P
41. isplay digits blink in sequence from left to right Pressing an arrow key immediately after a digit blinks alters that digit Releasing the arrow key causes the left to right sequencing to resume COLD INCH KEY This key energizes the wire feeder to inch the wire forward but does not energize the power source or solenoid valve GAS PURGE KEY This key energizes the solenoid valve to purge any remaining gasses but does not energize the wire feeder or power source ACCELERATION SETTING Pressing both the Gas Purge key and the Function Selection key at the same time on the keypad shown in Figure B 1 enables the acceleration setting display The LED display will indicate A X with X being a number from 1 slowest to 5 fastest This number is adjusted using the setting adjustment arrow keys To exit the acceleration setting function press both keys a second time or press any other key except for the setting adjustment arrow keys ENGLISH OR METRIC SPEED DISPLAY UNITS Pressing both the Gas Purge key and Timer Selection key causes the speed display units to toggle between inches per minute no decimal point displayed or meters per minute decimal point displayed If the LED display is showing the voltmeter or one of the timer settings when these keys are pressed the display will change to the weld speed to indicate the selected speed display units See Figure B 1 for key locations CIRCUIT PROTECTION The LN 742 has
42. ls is 5 64 in 2 0 mm K126 This Innershield gun and its cable assemblies are rated at 350 amps 60 duty cycle Maximum wire size for LN 742 models is 5 64 in 2 0 mm NOTE The K115 and K126 are not recommended for LN 742H models NOTE Linconditioner guns are recommended for locations where smoke accumulation is a problem and conventional exhaust systems are ineffective The available smoke removal type Innershield guns and vacuum units can be used in these locations Instructions are shipped with the equipment LN 742 amp LN 742H LINCOLN 8 C 4 ACCESSORIES 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 GMAW 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 appropriate Magnum literature for descriptions of the 200 400 ampere air cooled guns and cables that are available Gun cable lengths range from 10 to 25 ft 3 0 to 7 5 m and feed electrode sizes 0 025 in to 5 64 in 0 6 to 2 0 mm SPINDLES STANDS AND ADAPTERS There are a variety of spindles and wire reel adapters available for use with the LN 742 Select the desired setup according to your specific welding needs K162H SPINDLE The K162H spindle is used for mounting Readi Reels and 2 in 1 0 spools with a 60 Ib capacit
43. much as possible by hand DO NOT hammer on the spinner nut arms OPERATION B 10 A CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in back lashing of the coil which may tangle the wire A tangled coil will not feed It must be untangled or discarded 8 Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires 9 Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing it across the reel hub locking the reel in place FIGURE B 6 LOADING 50 OR 60 LB COIL SPINNER NUT d PLATE SLOTS CARDBOARD TIE WIRE SPRING LN 742 amp LN 742H LINCOLN B 11 WIRE REEL LOADING 50 AND 60 LB COILS K1524 1 UNIVERSAL WIRE REEL STAND TO MOUNT A 50 to 60 Ib 22 7 to 27 2 kg COIL USING K1504 1 COIL REEL FOR 50 to 60 Ib 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 in 51 mm spindle or with reel laying flat on the floor loosen the spinner nut and remove the reel cover See Figure B 7 2 Before cutting the tie wires place the coil of elec trode on the reel so
44. n Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Installation eurent es eue te anes Technical Specifications LN 742 Mounting Location Input Cable Connections Work Cable Meadow ied anda Gun and Cable Assemblies Gun Cable Connections Water Connections For Water Cooled Guns GMAW Shielding Gas Operation eee ne eee Operating Instructions Safety Precautions 1 General Description Recommended Processes and
45. nd welding machines 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other N moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 1 In some cases it be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electr
46. nders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PRECAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parrai
47. nnector end Inch the electrode through the gun and cable For solid wire cut the electrode within approximately 4 After the electrode has been removed connect 3 8 in of the end of the contact tip If using cored the gun conductor back to the wire feeder wire cut the electrode within 3 4 in of the extension guide 5 Load a new reel of electrode per the instructions Connect the work cable to the metal to be welded The work cable must make good electrical contact with the work The work must also be grounded for the specific reel type given previously in this section A WARNING When using an open arc process it is necessary to use correct eye head and body protection LN 742 amp LN 742H LINCOLN C1 ACCESSORIES C 1 GENERAL The following is a list of the accessories that can be A detailed description of each item is given later in this used with the LN 742 wire feeder section TABLE 1 LN 742 ACCESSORIES M11514 Wire Reel Dust Shield Door for K303 and K376 14543 Wire Reel Dust Shield for K376 50 to 60 Ib Wire Reel Mounting Stand LN 742 amp LN 742H LINCOLN 8 C 2 ACCESSORIES 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
48. ode and work cables If the electrode cable is on your right side the work cable should also be on your right side Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet 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 accidental contact with the workpiece
49. onnect the electrode lead to the power source output terminal of the desired polarity 3 Referring to Figure A 1 route the other end of the electrode cable through the large oval hole in the rear panel of the LN 742 case Connect the electrode to the copper strap on the side of the gearbox using the stud and nut provided FIGURE 1 INPUT CONTROL CABLE AND ELECTRODE CABLE CONNECTIONS CONTROL CABLE LN 742 amp LN 742H LINCOLN 8 3 INSTALLATION 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 assembly Put the input cable under the clamp and reinstall the screws The connection diagram Figure A 3 shows the electrode as positive To change polarity turn the power source off Reverse the electrode and work cables at the power source and set the wire feeder voltmeter polarity switch on the power source to the proper polarity Pins not listed in the table in Figure A 3 are not connected on the cable If using the K589 1 remote control kit set the power source control switch to the Remote position FIGURE A 2 STRAIN RELIEF CLAMP CONTROL CABLE STRAIN RELIEF CLAMP WIRE REEL MOUNTING ASSEMBLY ELECTRODE
50. op to bottom The top light indicates standard two step trigger mode In this mode the unit will only be active when the trigger is pressed The middle light indicates lock four step trigger mode In this mode the solenoid is energized when the trigger is pressed the power source and wire feeder are energized after preflow time when the trigger is released Closing the trigger a second time turns off the wire feeder and then the power source after burnback time Releasing the trigger a second time turns off the solenoid after Burnback time The bottom light indicates spot weld trigger mode Closing the trigger allows a single timed weld cycle The duration of the weld cycle is set with the time selection controls The spot on timer starts when welding current flows TIME SELECTION CONTROLS This control enables the operator to choose which timer will be displayed as shown by the indicator lights Pressing the key causes the mode lights to sequence from top to bottom Any timers not available to the currently selected mode will be skipped Times displayed in the LED display are adjusted using the setting adjustment arrows to the left of the LED display The top left light indicates the preflow time is being displayed in seconds The top right indicator light indicates the postflow time is being displayed in seconds The middle light indicates the burnback time is being displayed in seconds The bottom light indicates the spot weld tim
51. ou may remove the solenoid and screw the male fitting after applying sealant directly into the brass manifold block 1 Using male 5 8 18 UNF left hand thread fittings connect appropriate water hoses to the coolant inlet and outlet on the back of the LN 742 Connect the other ends of these hoses to the appropriate ports on your water cooling units In the event the water line fittings on your water cooled gun are incompatible with the female quick connects on the front of the LN 742 male quick connects are provided for installation on 3 16 in LD hose customer to provide appropriate clamps The feeder connectors self seal when disconnected FIGURE 5 WATER CONNECTIONS LN 742 amp LN 742H LINCOLN 8 7 INSTALLATION A 7 GMAW SHIELDING GAS HOOKUP A WARNING 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 Customer must provide a cylinder of shielding gas a pressure regulator a flow control valve and a hose from the flow valve to the gas inlet fitting of the LN 742 Install per Figure A 6 and the following 1 Connect the supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the LN 742 2 Install
52. our obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER ER TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret
53. peration for installation of drive rolls WIRE REEL MOUNTING To prolong the life of the reel shaft on the 50 to 60 Ib coils periodically coat it with a thin layer of grease No maintenance to the two position brake is required If the brake shoe wears through to metal replace the brake assembly No routine maintenance is required for Readi Reels and 10 to 30 lb spools Do not lubricate the 2 in spindles PERIODIC MAINTENANCE WIRE DRIVE MOTOR AND GEARBOX Every year inspect the gearbox and coat the gear teeth with a moly disulfide filled grease Do not use graphite grease Every six months check the motor brushes Replace them if they are less than 1 4 in long GUN AND CABLE MAINTENANCE For instructions on periodic maintenance for the welding gun and cables refer to the instructions included with your specific model of welding gun LN 742 amp LN 742H LINCOLN 8 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty 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 you locate and repair possible machine malfunctions Simply follow the th
54. ree step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as internal wiring Only qualified personnel should install use or ser vice this equipment CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 742 amp LN 742H LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual The display is blank No wire feed when the gun trigger is activated No wire feed when the gun trigger is activated The sol
55. roductive 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 amp 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 powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 1 To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND ES MAGNETIC FIELDS e may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables a
56. roll kits for each type of wire used TABLE C 2 DRIVE ROLL KIT NUMBERS Steel Wire Sizes 0 068 3 32 in 1 7 2 4 mm Cored 1 16 in 1 6 mm Cored or Solid 0 045 0 052 in 1 2 1 3 mm Solid 0 045 0 052 in 1 2 1 3 mm Cored 0 035 in 0 9 mm Solid 0 023 0 025 in 0 6 mm Solid Aluminum Wire Sizes 1 16 in 1 6 mm 3 64 in 1 2 mm 0 035 in 0 9 mm KP653 3 32C KP653 1 16 653 0525 653 052 653 0355 653 035 653 0305 653 0255 654 1 16 654 3 64 KP654 035A LN 742 amp LN 742H LINCOLN 8 KP655 3 32C KP655 1 16 KP655 052S KP655 052C KP655 035S KP655 035C KP655 030S KP655 025S KP656 1 16A KP656 3 64A KP656 035A C 6 D 1 MAINTENANCE D 1 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 sizes they will feed If a wire size other than that stamped on the rolls is to be used the rolls and guide tubes must be changed The drive rolls for 0 045 and 0 052 cored electrode and 1 16 0 068 5 64 3 32 and 7 64 electrode have a double set of teeth so they can be reversed for additional life Drive rolls for 0 023 through 0 052 solid electrodes have no teeth Refer to the instructions in Section B O
57. s See See in th for th DuC stickout as required for the procedure being used Set th larit itch T 11 To stop welding release the gun trigger and then connect the electrodes and work leads for the correct electrode polarity Set the voltage using the control on the power source or if used the optional K589 1 Remote Kit or K857 Remote Voltage Control Set the open circuit voltage to approximately 2 volts higher than the desired procedure voltage The final setting must be made according to the arc voltage while welding Use the Mode Selection key to set the desired operating mode Use the Function Selection key and Selection pull the gun away from the work after the arc goes out WIRE REEL CHANGING At the end of a coil remove the last of the old electrode from the conductor cable Either pull it out at the nozzle or use the following procedure 1 Cut off the end of the electrode at the gun end Do not break it off by hand Breaking by hand puts a slight bend in the wire making it difficult to pull it back through the nozzle Setting arrow keys to set the desired Inch and 2 Uncouple the gun conductor cable from the Weld Feed speeds conductor block on the wire feeder drive unit and lay the gun cable out straight Use the Time Selection key and Selection Setting arrow keys to set the desired timers 3 Using pliers grip the wire and pull it out of the cable from the co
58. s manual GENERAL DESCRIPTION The K617 LN 742 semiautomatic constant speed wire feeder is specifically equipped for gas metal arc welding using flux cored Outershield electrodes and solid wire The LN 742 is also suitable for self shielded flux cored Innershield electrodes submerged arc welding if constant voltage is satisfactory and other open arc welding It has been factory assembled with the following features e Wire feed control 50 to 770 in min 1 25 to 19 5 m min for the LN 742 80 to 1200 in min 2 00 to 30 5 m min for the LN 742H Factory installed gas solenoid valve and gas fittings e Wire drive uses a permanent magnet motor and includes tool less quick release idle roll pressure arm outgoing guide tube and gun cable fastening Optional factory installed water solenoid and fittings for use with water cooled welding guns The LN 742 4 Roll is designed to provide the additional feeding force required when using gun cables over 15 ft 4 6 m long or when the wire is pulled long distances such as when bulk packages are used Because the four roll feeder has twice the contact surface it can also help when feeding softer wires by delivering the same or more feeding force as the two roll with less overall wire deformation RECOMMENDED PROCESSES AND EQUIPMENT The LN 742 is recommended for use in MIG and Innershield welding applications with constant voltage power sources with 42 VAC auxiliary power and
59. sent at the welder output termi nals If no voltage is present at the output terminals the power source is faulty The control cable may be faulty Check leads 2 and 4 pins C and D for continuity zero ohms The welding cables may me faulty Check for loose or faulty connections The gun may be faulty Check or replace If all recommended possible areas of The wire feeds when the gun trig 1 Check for loose or faulty con Misadjustment have been checked ger is activated but there is no con nections between the tach and and the problem persists Contact trol of the wire feed speed the control board plug J3 your local Lincoln Authorized Field Service Facility The wire feed speed does not 1 The inch and weld speeds change when welding current be set to the same value begins to flow If the display shows the symbol the inch speed has been disabled To enable the inch speed press the increase arrow key Check plug J2 on the control board for loose or faulty con nections CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed LN 742 amp LN 742H LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE O
60. should be aligned towards the drive roll Slide the guide tube up against the installed drive roll Install the second drive roll on the remaining shaft the same way as the first Center the middle guide tube between the rolls and tighten the thumbscrews holding it in place Close and latch both quick release levers Slide the longer guide tube into the rear hole of the gearbox until it almost touches the drive roll and guide tube Tighten the thumbscrew to hold it in place Install the outgoing guide tube into the front hole of the gearbox through the conductor block and tighten the thumb screw The 0 035 in outgoing guide tube should have the larger radius oriented toward the drive roll For proper installation of the outgoing guide tube insert refer to Figure B 3 Be certain that the guide tubes do not touch the drive rolls or idle rolls If they do touch readjust them and tighten in place LN 742 amp LN 742H LINCOLN B6 FIGURE INSTALLING DRIVE ROLLS FOUR ROLL FEEDER CLAMPING COLLAR DRIVE ROLL HALVES SPACER IF REQUIRED n 2 OUTPUT TL SHAFT GUIDE TUBE DETAIL LARGE RADIUS coon 6 RE Bp DLE MIDDLE ROLL GUIDE SMALL TUBE RADIUS LN 742 amp LN 742H LINCOLN B 7 OPERATION B 7 IDLE ROLL PRESSURE SETTING 2 The idle roll pressure is se
61. ssent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jama
62. t 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 varies with type of wire surface condition lubrication and hardness The optimum idle roll setting can be determined as follows Two roll wire feeders 1 Press the end of the gun against a solid object that is electrically isolated from the welder output and press the trigger for several seconds 2 If the wire birdnests jams or breaks at the drive roll the idle roll pressure is set too high Back the pressure adjustment knob Figure B 4 out 1 2 turn Run new wire through the gun and repeat step 1 3 If the only result is drive roll slippage loosen the gun cable clamping screw on the conductor block and pull the gun cable forward about six inches There should be a slight waviness in the exposed wire If there is no waviness the pressure is too low Increase the pressure setting 1 4 turn Lock the gun cable in place and repeat steps 1 and 2 Four roll wire feeders 1 Release the incoming idle roll and perform the pressure setting procedure for two roll feeders to set outgoing idle roll pressure After outgoing pressure is set determine how many turns away from full pressure the setting is Set both idle roll tensions to this setting Engag
63. the barbed fitting and union nut to the 5 8 18 female inert gas fitting on the front of the LN 742 Connect 3 16 4 8 mm I D gas hose from the gun to the barbed fitting When the gun is to be removed this fitting can be easily detached by loosening the union nut The LN 742 can be used with any shielding gas recommended in the electrode s product literature at a maximum pressure of 60 psi 4 1 bar This may include gasses such as Argon Helium and Nitrogen and blended gases such as Ar He 2 Ar CO 2 FIGURE 6 SHIELDING GAS HOOKUP GAS HOSE FITTING LN 742 amp LN 742H LINCOLN 8 B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand the entire Operation Section prior to operating the machine SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK Y o can kill Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work or ground Always wear dry gloves FUMES AND GASES can be dangerous insulating Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 1 2 Wear eye ear protection Observe additional Safety Guidelines detailed in the beginning of thi
64. y on a K303 or K376 Wire Reel Stand When used with Readi Reels a Readi Reel Adapter is required For 8 in O D spools a K468 Spindle Adapter is available K363P 22 TO 30 LB READI REEL ADAPTER Adapts Lincoln Readi Reel coils of 22 and 33 Ib 10 and 14 kg to a 2 in 51 mm spindle Durable molded plastic one piece construction Designed for easy loading adapter remains on spindle for quick changeover Included with K377 K376 AND K303 50 TO 60 LB WIRE REEL MOUNTING STANDS K376 50 to 60 Ib Wire Reel Mounting Stand and the K303 Wire Reel Mounting Stand are the same with the exception that the K303 stand includes a dust shield The assembly includes a framework to which is attached the 50 to 60 Ib wire reel a mounting spindle a lift bale and a cable clamp for fastening the input cable assembly It is easily mounted to the basic wire feed unit by following the Attaching the Wire Reel Stand procedure at the end of this section UNIVERSAL WIRE REEL STAND K1524 1 Includes a 2 b1mm O D Spindle with adjustable brake and two locations for mounting the spindle to allow for the mounting of 50 60lb 10 30 Ib 13 1415 and 8 O D coils with proper spindle adapters See OPERATION section Capable of being mount ed on the top of a suitable power source or surface without the need for any other mounting kit Optional features available for this stand include e K1555 1 insulated lift bale e 1556 1 caster kit

Lincoln LN-742H Welder User Manual

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