LN-742 & LN-742H Wire Feeders: Operator'S Manual

IM502-A
LN-742 & LN-742H Wire Feeders June, 2000
For use with machines having Code Numbers: 10029

10030
10234
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
10235
Specifications and availability of optional 10236
features may have changed.
10237
10046
10047
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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
• 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers before welding.
and devices in position and in good
repair.Keep hands, hair, clothing and tools 2.c. Exposure to EMF fields in welding may have other health
away from V-belts, gears, fans and all other effects which are now not known.
moving parts when starting, operating or
repairing equipment. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d.1. Route the electrode and work cables together - Secure
guards to perform required maintenance. Remove them with tape when possible.
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.2. Never coil the electrode lead around your body.
Always use the greatest care when working near moving
parts. 2.d.3. Do not place your body between the electrode and
___________________________________________________ work cables. If the electrode cable is on your right
1.f. Do not put your hands near the engine fan. Do not attempt side, the work cable should also be on your right side.
to override the governor or idler by pushing on the throttle
control rods while the engine is running. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar ‘95
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling. products.
3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

Mar ‘95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
a. Les circuits à l’électrode et à la piéce sont sous tension de la zone de travail qu’il est pratique de le faire. Si on place
quand la machine à souder est en marche. Eviter toujours la masse sur la charpente de la construction ou d’autres
tout contact entre les parties sous tension et la peau nue endroits éloignés de la zone de travail, on augmente le risque
ou les vétements mouillés. Porter des gants secs et sans de voir passer le courant de soudage par les chaines de lev-
trous pour isoler les mains. age, câbles de grue, ou autres circuits. Cela peut provoquer
b. Faire trés attention de bien s’isoler de la masse quand on des risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher câbles jusqu’à ce qu’ils se rompent.
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions voir le code “Code for safety in welding and cutting” CSA
pour le porte-électrode s’applicuent aussi au pistolet de Standard W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

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

soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
••• 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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
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:
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.
TABLE OF CONTENTS vi
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - LN-742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Input Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Gun Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Water Connections (For Water Cooled Guns) . . . . . . . . . . . . . . . . . . . . . A-6
GMAW Shielding Gas Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . B-1
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Acceleration Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
English or Metric Speed Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Drive Roll Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Idle Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Wire Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Wire Reel Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Flux System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Power Input Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Welding Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Spindles, Stands, and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Attaching the Wire Reel Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
How To Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Electrical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix
LN-742 & LN-742H

A-1 INSTALLATION A-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 CORED 0.045 in. through 3/32 in. (1.2 through 2.4 mm)
LN-742H CORED 0.045 in. (1.2 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 10.52 in. 9.76 in. 10.89 in. 24.3 lbs
WITHOUT WIRE STAND (267 mm) (247 mm) (277 mm) (11.1 kg)
WITH WIRE STAND (K377) (548 mm) (247 mm) (432 mm) (15.6 kg)
WITHOUT WIRE STAND (292 mm) (295 mm) (282 mm) (13.2 kg)
WITH WIRE STAND (K377) (573 mm) (295 mm) (432 mm) (17.8 kg)
ENVIRONMENTAL RATING (ALL MODELS)

IP21 (IEC 974-5)
LN-742 & LN-742H

MOUNTING LOCATION
The LN-742 wire feeders can be mounted directly on 1. Connect the end of the control cable with the 14-
top of the power source providing that it is secure and pin cable plug to the mating receptacle on the
level. The LN-742 can also be mounted to an power source.
undercarriage when portability is required. The LN-742
should be installed upright on a horizontal surface. 2. Connect the electrode lead to the power source
output terminal of the desired polarity.
A K178-1 mounting platform is available for mounting
the LN-742 to the top of Idealarc power sources. Refer 3. Referring to Figure A.1, route the other end of the
to Section C, Accessories, for details. 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.
INPUT CABLE CONNECTIONS
Refer to Section C, Accessories, for descriptions of FIGURE A.1 – INPUT CONTROL CABLE AND
the various input cable assemblies available for the ELECTRODE CABLE CONNECTIONS.
LN-742 wire feeder.
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. CONTROL
CABLE
With input power disconnected at the source, install
the input cable per connection diagram A.3, and NUT
complete the following instructions:
COPPER ELECTRODE
STRAP STUD
LN-742 & LN-742H

4. Connect the remaining end of the control cable FIGURE A.2 – STRAIN RELIEF CLAMP.
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.
CONTROL
The connection diagram, Figure A.3, shows the CABLE
electrode as positive. To change polarity, turn the
power source off. Reverse the electrode and work STRAIN
cables at the power source, and set the wire feeder RELIEF
voltmeter polarity switch on the power source to the CLAMP
proper polarity.
Pins not listed in the table in Figure A.3 are not

connected on the cable.
WIRE REEL
If using the K589-1 remote control kit, set the power MOUNTING ELECTRODE
source control switch to the “Remote” position. ASSEMBLY CABLE
LN-742 & LN-742H

FIGURE A.3 – LN-742 WIRE FEEDER TO LINCOLN POWER SOURCE – CONNECTION DIAGRAM.
WARNING 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
I=41 I=41
C=2 H=21 H=21 C=2
D=4 G=75 G=75 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 75 OUTPUT CONTROL
H 21 WORK
I 41 42V AC
K 42 42V AC
FUNCTIONS ARE LISTED FOR REFERENCE
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQUIPMENT.
CLEVELAND, OHIO U.S.A
LN-742 & LN-742H

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 50 Ft 50 Ft-100 Ft
Duty Cycle (15.2 m) (15.2-30.4 m)
300 Amps 0 (53 mm2) 00 (67 mm2)
400 Amps 00 (67 mm2) 000 (85 mm2)
500 Amps 00 (67 mm2) 000 (85 mm2)
600 Amps 000 (85 mm2) 0000 (107 mm2)
GUN AND CABLE ASSEMBLIES

An expanding line of Magnum Fast-Mate 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 to 400 ampere air cooled gun and cables
that are available. Gun cable lengths range from 10 ft.
(3.0m) to 25 ft. (7.6m) and feed electrode sizes .025”
(0.6mm) to 5/64” (2.0mm).
An expanding line of Magnum X-Tractor gun and cable

assemblies provides fume extraction capability for
welding with solid and cored electrodes using the
GMAW process. See the appropriate Magnum
literature for descriptions of the 250 to 400 ampere air
cooled gun and cables that are available. Gun cable
lengths range from 10 ft. (3.0 m) to 15 ft. (4.5 m) and
feed electrode sizes .035” (0.9 mm) to 1/16” (1.6 mm).
These guns require the use of either the K173-1 or
K184* vacuum units.
* Requires S14927-8 connector hose and an S20591 hose adapter.
LN-742 & LN-742H

WATER CONNECTIONS 1. Using male 5/8-18 UNF left-hand thread fittings,

connect appropriate water hoses to the coolant
(FOR WATER COOLED GUNS) inlet and outlet on the back of the LN-742.
Connect the other ends of these hoses to the
The LN-7 GMA must have a K590-1 Water Solenoid appropriate ports on your water cooling units.
Kit installed (see Section C, Accessories). Refer to
Figure A.4 and perform the following steps: 2. In the event the water line fittings on your water
cooled gun are incompatible with the female quick
The maximum water pressure permitted for use with connects on the front of the LN-742, male quick
the LN-742 is 55 psi (3.8 bar). connects are provided for installation on 3/16 in.
I.D. hose (customer to provide appropriate
NOTE: If not using a Lincoln water cooler, and if your clamps). The feeder connectors self seal when
water cooling device is not designed for use with a disconnected.
waterline solenoid valve, you may remove the solenoid
and screw the male fitting (after applying sealant)
directly into the brass manifold block.
FIGURE A.4 – WATER CONNECTIONS.
FRONT
BACK
LN-742 & LN-742H

GMAW SHIELDING GAS HOOKUP 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.
WARNING Install per Figure A.5 and the following:
Gas under pressure is explosive.
Always keep gas cylinders in an 1. Connect the supply hose from the gas cylinder
upright position and chained to the flow valve outlet to the 5/8-18 female inert gas
undercarriage or a stationary fitting on the back panel of the LN-742.
support. See American National
Standard Z-49.1, “Safety In Welding The LN-742 can be used with any shielding gas
And Cutting”, published by the recommended in the electrode’s product literature at a
American Welding Society. 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, Ar-N2, Ar-O2, Ar-
CO2, CO2, AR-CO2,-O2.
FIGURE A.5 – SHIELDING GAS HOOKUP.
GAS
SUPPLY
HOSE
LN-742 & LN-742H

B-1 OPERATION B-1
OPERATING INSTRUCTIONS GENERAL DESCRIPTION

Read and understand the entire Operation Section The LN-742 semiautomatic constant speed wire feeder
prior to operating the machine. 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
SAFETY PRECAUTIONS constant voltage is satisfactory), and other open arc
welding. It has been factory assembled with the
WARNING following features:
• Wire feed control [50 to 770 in./min (1.25 to 19.5

ELECTRIC SHOCK m/min) for the LN-742; 80 to 1200 in./min (2.00 to
can kill. 30.5 m/min) for the LN-742H].
• Do not touch electrically live parts • Factory installed gas solenoid valve and gas
or electrode with skin or wet fittings.
clothing.
• Wire drive uses a permanent magnet motor and
• Insulate yourself from work or includes tool-less “quick-release” idle roll pressure
ground. arm, outgoing guide tube and gun cable fastening.
• Always wear dry insulating • Optional factory installed water solenoid and fittings
gloves. for use with water cooled welding guns.
FUMES AND GASES The LN-742 4-Roll is designed to provide the additional
can be dangerous. feeding force required when using gun cables over 15
ft (4.6 m) long or when the wire is pulled long distances
• Keep your head out of fumes. (such as when bulk packages are used). Because the
four-roll feeder has twice the contact surface, it can
• Use ventilation or exhaust to also help when feeding softer wires by delivering the
remove fumes from breathing same or more feeding force as the two-roll with less
zone. overall wire deformation.
WELDING SPARKS
can cause fire or explosion.
RECOMMENDED PROCESSES AND
EQUIPMENT
• Keep flammable material away.
The LN-742 is recommended for use in MIG and
• Do not weld on containers that Innershield welding applications with constant voltage
have held combustibles. power sources with 42 VAC auxiliary power and a 14-
pin connector receptacle, such as the Invertec V300-
ARC RAYS PRO, DC-650-PRO, or Lincoln CV type power
can burn. sources.
• Wear eye, ear, and body The LN-742 is capable of the following wire feed
protection. ranges:
Observe additional Safety Guidelines detailed in • 0.025 to 1/16 in. (0.6 to 1.6 mm) solid wire for gas-
the beginning of this manual. 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 & LN-742H

B-2 OPERATION B-2
• 0.045 to 5/64 in. (1.2 to 2.0 mm) cored wire for this mode the unit will only be active when the trigger
Innershield processes. is pressed. The middle light indicates lock (four-step)
trigger mode. In this mode the solenoid is energized
The LN-742H is capable of the following wire feed when the trigger is pressed, the power source and
ranges: wire feeder are energized after preflow time when the
trigger is released. Closing the trigger a second time
• 0.025 to 0.045 in. (0.6 to 1.2 mm) solid wire for gas- turns off the wire feeder and then the power source
metal-arc or CV submerged arc processes. after burnback time. Releasing the trigger a second
• 0.045 in. (1.2 mm) cored wire for Outershield gas- time turns off the solenoid after Burnback time. The
metal-arc or Innershield processes. bottom light indicates spot weld trigger mode. Closing
the trigger allows a single, timed, weld cycle. The
CONTROLS AND SETTINGS duration of the weld cycle is set with the time selection
controls. The spot on timer starts when welding
The operator controls are located on the keypad current flows.
shown in Figure B.1. The keypad consists of: 7
membrane keys with tactile-feel embossed domes, TIME SELECTION CONTROLS. This control enables
that are generously spaced to provide easy selection, the operator to choose which timer will be displayed
even while wearing welding gloves; a long-life, 3-1/2 as shown by the indicator lights. Pressing the key
digit, 7 segment LED display with 0.56 in. (14.2 mm) causes the mode lights to sequence (from top to
character height, permitting easy viewing even from bottom). Any timers not available to the currently
long gun cable distances; and high intensity, red, LED selected mode will be skipped. Times displayed in the
indicator lights that allow for viewing at almost any LED display are adjusted using the setting adjustment
angle. arrows to the left of the LED display. The top left light
indicates the preflow time is being displayed in
TRIGGER MODE CONTROLS. This control enables seconds. The top right indicator light indicates the
the operator to choose the mode of operation as postflow time is being displayed in seconds. The
shown by the indicator lights. Pressing the key causes middle light indicates the burnback time is being
the mode lights to sequence (from top to bottom). The displayed in seconds. The bottom light indicates the
top light indicates standard (two-step) trigger mode. In spot weld time is being displayed in seconds.
FIGURE B.1 – WIRE FEEDER CONTROLS.
COLD GAS
INCH PURGE
KEY KEY
COLD INCH GAS PURGE
SETTING
ADJUSTMENT LED
ARROW KEYS OLTMETER DISPLAY
INCH
WFS
FUNCTION
SELECTION
CONTROLS
TRIGGER MODE TIME

PREFLOW POSTFLOW
STD t1 t2
TIMER
LOCK t BURNBACK
SELECTION
TRIGGER SPOT t SPOT CONTROLS
MODE
CONTROLS t
LN-742 & LN-742H

B-3 OPERATION B-3
FUNCTION SELECTION CONTROLS. This control ENGLISH OR METRIC SPEED

enables the operator to select the function that will be
displayed as shown by the indicator lights. Pressing DISPLAY UNITS
the key causes the mode lights to sequence (from top
to bottom). Settings displayed in the LED display are Pressing both the Gas Purge key and Timer Selection
adjusted using the setting adjustment arrows to the key causes the speed display units to toggle between
left of the LED display. The top light indicates the arc inches per minute (no decimal point displayed) or
voltage is being displayed in volts. The middle light meters per minute (decimal point displayed). If the LED
indicates the inch speed is being displayed. The display is showing the voltmeter or one of the timer
bottom light indicates the weld feed speed (WFS) is settings when these keys are pressed, the display will
being displayed. change to the weld speed to indicate the selected
speed display units. See Figure B.1 for key locations.
INCREASE ARROW. This key increases the setting
of the parameter selected to be displayed, using the
“Quick-Set” feature for fast and accurate setting. CIRCUIT PROTECTION
DECREASE ARROW. This key decreases the setting The LN-742 has solid-state overload protection of the
of the parameter selected to be displayed, using the wire drive motor. If the wire drive motor becomes
“Quick-Set” feature for fast and accurate setting. overloaded for an extended period of time, the
protection circuitry turns off the power source, wire
QUICK-SET FEATURE. This feature permits the feeder, and solenoid, then displays the error code E30
arrow keys to control each display digit one at a time. on the LED display. This indicates the wire drive motor
The display digits blink in sequence from left to right. is overloaded, with the number indicating the time
Pressing an arrow key immediately after a digit blinks remaining in seconds before the unit will automatically
alters that digit. Releasing the arrow key causes the reset. This number continues to decrement every
left-to-right sequencing to resume. second until it reaches zero. At that time the unit
resets automatically and the previous display will
COLD INCH KEY. This key energizes the wire feeder return indicating that the unit is ready for operation.
to inch the wire forward, but does not energize the
power source or solenoid valve. Over loads can result from: improper tip size, liner,
drive rolls, or guide tubes; obstructions or bends in the
GAS PURGE KEY. This key energizes the solenoid gun cable; feeding wire that is larger than the rated
valve to purge any remaining gasses, but does not capacity of the feeder; or any other factors that would
energize the wire feeder or power source. impede normal wire feeding.
ACCELERATION SETTING DRIVE ROLL INSTALLATION

Pressing both the Gas Purge key and the Function CHANGING DRIVE ROLLS FOR TWO-
Selection key at the same time, on the keypad shown
in Figure B.1, enables the acceleration setting display.
ROLL WIRE FEEDERS:
The LED display will indicate “A-X” with “X” being a
number from 1 (slowest) to 5 (fastest). This number is To change drive rolls on a two-roll wire feeder, refer to
adjusted using the setting adjustment arrow keys. To Figure B.2 and perform the following steps:
exit the acceleration setting function, press both keys a
second time, or press any other key except for the 1. Turn off the welding power source.
setting adjustment arrow keys.
2. Rotate the latch knob on the quick release arm.
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.
LN-742 & LN-742H

B-4 OPERATION B-4
FIGURE B.2 – INSTALLING DRIVE ROLLS ON A TWO-ROLL FEEDER.
CLAMPING
COLLAR
SPACER (IF REQUIRED)

DRIVE
ROLL
HALVES
OUTPUT
SHAFT
GUIDE TUBE DETAIL LARGE

RADIUS
OUTGOING DRIVE
GUIDE ROLL
TUBE
OUTGOING
GUIDE TUBE
INSERT
IDLE INCOMING
ROLL GUIDE
SMALL TUBE
RADIUS
LN-742 & LN-742H

B-5 OPERATION B-5
5. Use the clamping collar and hex head screw to 4. Loosen the thumb screws holding the guide tubes
install the roll on the output shaft. Certain size drive in place. Remove the incoming guide tube, if
rolls consist of two roll halves, and may contain a installed.
spacer. If the drive roll you are installing contains a
spacer, the spacer fits between the two halves of 5. Remove the hex head screws and clamping
the drive roll. Double grooved drive rolls are to be collars from the output shafts. Remove the drive
installed with side stenciled for correct wire size rolls and middle guide tube.
facing outward and with slotted spacer on top of
roll. Tighten the hex head screw. 6. The new rolls to be installed are stenciled with the
wire size that will be fed. An “A” after the number
6. Loosen the molded hand-screw on the front of the indicates aluminum wire. Remove the rolls from
wire drive and pull the gun connector out of the the kit and wipe them clean. Wipe the output
connector block. The guide tube provided in the shafts and locating shoulders clean.
gun connector is for .045” (1.2mm) or smaller wire
sizes (marked with one ring). If larger wire sizes 7. Install one roll onto the output shaft closest to the
are used, remove and replace the guide tube with incoming side of the feeder clamping collar and
the larger hole guide tube (marked with four rings) hex head screw. Certain size drive rolls consist of
which is provided in the storage hole of two roll halves, and may contain a spacer. If the
appropriate capacity wire drive faceplates (near drive roll you are installing contains a spacer, the
motor). The guide tube is secured with a set spacer fits between the two halves of the drive
screw on the bottom of the brass hex so the guide roll. Double grooved drive rolls are to be installed
tube is flush with the incoming end of the gun with side stenciled for correct wire size facing
connector. outward and with slotted spacer on top of roll.
Tighten the hex head screw.
7. Back out the guide tube clamping screws.
Remove the old guide tubes, if installed. 8. Install the middle guide tube, but do not tighten at
this time. When installing a 0.035” middle guide
8. Insert the longer guide tube into the rear hole and tube the larger radius should be aligned towards
the other guide tube through the front hole. The the drive roll. Slide the guide tube up against the
fine wire chisel point end of the guide tube must installed drive roll.
have the larger radius end next to the drive roll.
See Figure B.2. Push the guide tube back as far 9. Install the second drive roll on the remaining shaft
as it will go and tighten the clamping screw. Insert the same way as the first. Center the middle guide
the incoming guide tube as far back as it will go tube between the rolls and tighten the
and tighten the clamping screw. The clamping thumbscrews holding it in place.
screws are dog points. When the guide tubes are
properly installed these dog points will lock into 10. Loosen the molded hand-screw on the front of the
the annular grooves in each of the guide tubes. wire drive and pull the gun connector out of the
connector block. The guide tube provided in the
9. Re-install the gun connector into the conductor gun connector is for .045” (1.2mm) or smaller wire
block and tighten the molded hand-screw. sizes (marked with one ring). If larger wire sizes
are used, remove and replace the guide tube with
10. Re-latch the idle roll pressure arm. the larger hole guide tube (marked with four rings)
which is provided in the storage hole of
11. Set the idle roll pressure as detailed in the Idle appropriate capacity wire drive faceplates (near
Roll Pressure Setting procedure detailed later in motor). The guide tube is secured with a set
this section. screw on the bottom of the brass hex so the guide
tube is flush with the incoming end of the gun
connector.
CHANGING DRIVE ROLLS FOR FOUR-
11. With the gun connector removed, back out the
ROLL WIRE FEEDERS: screws for the outgoing guide tube.
To change drive rolls on a four-roll wire feeder, refer to
12. Install the outgoing guide tube in the front hole.
Figure B.3 and perform the following steps:
Be certain that the proper plastic insert is used.
For proper installation of the outgoing guide tube
1. Turn off welding power source.
insert, refer to Figure B.3. The fine wire chisel
point tube must have largest radius next to drive
2. Remove the gun and cable.
roll. Tighten in place.
3. Open both quick release levers by moving the
13. Re-install the gun connector into the conductor
levers outward and pulling them toward you.
block and tighten the molded hand-screw.
LN-742 & LN-742H

B-6 OPERATION B-6
FIGURE B.3 – INSTALLING DRIVE ROLLS ON A FOUR-ROLL FEEDER.
CLAMPING
COLLAR
DRIVE
ROLL
HALVES
SPACER
(IF REQUIRED)
OUTPUT
SHAFT
GUIDE TUBE DETAIL LARGE

RADIUS
OUTGOING
GUIDE
TUBE
OUTGOING
GUIDE TUBE
INSERT
IDLE MIDDLE
ROLL GUIDE
SMALL TUBE
RADIUS
LN-742 & LN-742H

B-7 OPERATION B-7
14. Slide the longer incoming guide tube into the rear
hole of the gearbox until it almost touches the FIGURE B.4 – IDLE ROLL PRESSURE SETTING.
drive roll and guide tube. Tighten the thumbscrew
to hold it in place.
15. 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.
16. Close and latch both quick release levers.
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 varies
with type of wire, surface condition, lubrication, and
hardness. The optimum idle roll setting can be
determined as follows:
PRESSURE
Two-roll wire feeders: ADJUSTMENT
KNOB
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.
2. After outgoing pressure is set, determine how
many turns away from full pressure the setting is.
3. Set both idle roll tensions to this setting. Engage

both idle rolls before welding. For most
applications, best wire feeding will occur when
both idle roll pressures are set the same.
LN-742 & LN-742H

B-8 OPERATION B-8
WIRE LOADING 6) Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
Loading a 22 to 30 Lb. (10 to 14 kg) Readi-Reel 7) Lower the Readi-Reel to depress the retaining
Package Using the Molded Plastic K363-P spring and align the other inside cage wires with
Readi-Reel Adapter: the grooves in the molded adapter.
The Spindle should be located in the LOWER mounting hole 8) Slide the cage all the way onto the adapter until
of the K1524-1 Universal Stand if used. the retaining spring "pops up" fully.
1) Depress the Release Bar on the Retaining Collar and WARNING

remove it from the spindle. NOTE: Earlier spindles
used a threaded collar. See Figure B.5a or B.5b. Check to be sure the Retaining Spring has fully
returned to the locking position and has SECURELY
2) Place the Adapter on the spindle. locked the Readi-Reel Cage in place. Retaining
Spring must rest on the cage, not the welding elec-
3) Re-install the Retaining Collar. Make sure that the trode.
Release Bar “pops up” and that the collar retainers ___________________________________________
fully engage the retaining groove on the spindle.
9) To remove Readi-Reel from Adapter, depress
4) Rotate the spindle and adapter so the retaining retaining spring tab with thumb while pulling the
spring is at the 12 o'clock position. Readi-Reel cage from the molded adapter with
both hands. Do not remove adapter from spindle.
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) FIGURE B.5b (Retaining Collar)

2 IN. O.D. SPINDLE ADAPTER
RETAINING SPRING
BRAKE
HOLDING
PIN
GROOVES
READI-REEL
INSIDE CAGE WIRES THREADED

LOCKING
COLLAR
LN-742 & LN-742H

B-9 OPERATION B-9
TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS 2. While tightly holding the electrode, cut off the bent
(12 in./300 mm DIAMETER) OR 13-14 lb (6 kg) end and straighten the first six inches. Cut off the
INNERSHIELD COILS: first inch. (If the electrode is not properly
straightened, it may not feed or may not go into
The spindle should be located in the lower mounting the outgoing guide tube, causing a “birdnest”.)
hole of the K1524-1 Universal Stand if used.
3. Insert the free end through the incoming guide
[For 8 in. (200 mm) spools, a K468 spindle adapter tube.
must first be slipped onto the spindle.]
4. Press the cold inch key or gun trigger and push
[For 13 to 14 lb (6 kg) Innershield coils, a K435 Coil the electrode into the drive roll.
Adapter must be used.]
1. Depress the Release Bar on the Retaining Collar

WARNING
and remove it from the spindle. NOTE: Earlier ELECTRIC SHOCK
spindles used a threaded collar. See Figure B.5a or can kill.
B.5b.
• Do not touch electrically live parts
2. Place the spool on the spindle, making certain such as output terminals or
the spindle brake pin enters one of the holes in internal wiring.
the backside of the spool. Be certain the wire
comes off the reel in a direction so as to de-reel • When inching with the gun
from the bottom of the coil. trigger, electrode and drive
mechanism are “hot” to work and
3. Re-install the Retaining Collar. Make sure that ground and could remain “hot” for
the Release Bar “pops up” and that the collar several seconds after the gun
retainers fully engage the retaining groove on the trigger is released.
spindle. ------------------------------------------------------------------------
5. Inch the electrode through the gun.
ELECTRODE FEEDING AND BRAKE 6. Adjust the brake tension with the thumbscrew on
ADJUSTMENT the spindle hub until the reel turns freely but with
little or no overrun when wire feeding is stopped.
1. Turn the Readi-Reel or spool until the free end of Do not overtighten.
the electrode is accessible.
LN-742 & LN-742H

B-10 OPERATION B-10
WIRE REEL LOADING – 50 AND 60 LB

CAUTION
COILS (K303 OR K376 WIRE REEL STAND)
Always be sure the free end of the coil is securely held
ADJUSTABLE WIRE REEL BRAKE
while the tie wires are being cut and until the wire is
feeding through the drive rolls. Failure to do this will
The mount for standard 50 and 60 pound electrode
result in “back lashing” of the coil, which may tangle the
coils includes a two-position brake assembly.
wire. A tangled coil will not feed. It must be untangled
Generally the brake should be at the inner position
or discarded.
(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
8. Cut and remove only the tie wire holding the free
feeding smaller diameter electrode.
end of the coil. Insert the free end into one of the
holes in the cover and secure it by bending it
To adjust the brake position, remove the wire reel. Pull
back. Cut and remove the remaining tie wires.
the cotter pin that holds the brake shoe to the arm,
move the shoe and replace the cotter pin. Do not bend
9. Replace the reel on the wire feeder. Grasp the
the cotter pin - it is held in place by a friction fit.
shaft knob, pull it out and swing it across the reel
hub, locking the reel in place.
TO MOUNT A 50 OR 60 LB COIL:
FIGURE B.6 – LOADING 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. SPINNER
NUT
Remove the reel.
COVER
2. Lay the reel flat on the floor. Loosen the spinner PLATE
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 SLOTS

arms will not interfere with the later removal of the
CARDBOARD
coil tie wires. COIL
LINER
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 COIL
compression of the coil sides needed for trouble-
free wire feeding.
TIE WIRE
6. Put the cover plate on the reel so the four arms of
the cover plate straddle and are in line with the REEL SPRING
spring loaded arms of the reel. LOADED
ARM
7. Tighten the cover as much as possible by hand.
DO NOT hammer on the spinner nut arms.
LN-742 & LN-742H

B-11 OPERATION B-11
WIRE REEL LOADING – 50 AND 60 LB FIGURE B.7 – K1504-1 COIL REEL.

COILS (K1524-1 UNIVERSAL WIRE REEL
SPINNER NUT
STAND)
TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL:

(USING K1504-1 COIL REEL) (FOR 50 to 60 lb COVER
READI-REELS A K438 READI-REEL ADAPTER PLATE
MUST BE USED.)
The spindle should be located in the UPPER mount-

ing hole.
SLOTS
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 CARDBOARD
cover. See Figure B.7. COIL LINER
2. Before cutting the tie wires, place the coil of elec-

trode on the reel so it unwinds from the bottom
COIL
as the reel rotates.
3. Tighten the spinner nut against the reel cover as

much as possible by hand, using the reel cover TIE WIRE
spokes for leverage. DO NOT hammer on the
spinner nut arms.
SPRING
LOADED ARM
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. REEL
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 & LN-742H

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.
1. Use only constant voltage power type sources. If
using a multiple process power source, be sure it 10. Lower your welding helmet. Close the gun trigger
is set for constant voltage output per instructions and begin welding. Hold the gun so the contact tip
in the manual for the power source. to work distance gives the correct electrical
stickout as required for the procedure being used.
2. Set the power source polarity switch or properly
connect the electrodes and work leads for the 11. To stop welding, release the gun trigger and then
correct electrode polarity. pull the gun away from the work after the arc goes
out.
3. Set the voltage using the control on the power
source or, if used, the optional K589-1 Remote Kit WIRE REEL CHANGING
or K857 Remote Voltage Control. Set the open
circuit voltage to approximately 2 volts higher At the end of a coil, remove the last of the old electrode
than the desired procedure voltage. The final from the conductor cable. Either pull it out at the
setting must be made according to the arc voltage nozzle, or use the following procedure:
while welding.
1. Cut off the end of the electrode at the gun end. Do
4. Use the Mode Selection key to set the desired not break it off by hand. Breaking by hand puts a
operating mode. slight bend in the wire, making it difficult to pull it
back through the nozzle.
5. Use the Function Selection key and Selection
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.
6. 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 connector end.
7. 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
for the specific reel type given previously in this
8. Connect the work cable to the metal to be welded. section.
The work cable must make good electrical
contact with the work. The work must also be
grounded.
WARNING
When using an open arc process, it is necessary to
use correct eye, head, and body protection.
------------------------------------------------------------------------
LN-742 & LN-742H

C-1 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 C.1 – LN-7 GMA ACCESSORIES.
Product Number Name

K163 Undercarriage
K178-1 Mounting Platform
K589-1 Remote Control Kit
K590-1 Water Solenoid Kit
K590-2 Water Connection Kit
K857 Remote Voltage Control Kit
K58 Magnetic Separator
K310 Flux Screen
K320 Flux Tank
K591 Input Cable - 400 Amps
K593-10 Input Cable and Gas Hose - 400 Amps
K162H Spindle
K363P 22 to 30 lb Readi-Reel Adapter
K376 and 303 50 to 60 lb Wire Reel Mounting Stands
K1524-1 Universal Wire Reel Stand - 2” Spindle
K1504-1 60 lb Coil Adapter for K1524-1 Stand
K1551-1 Insulated Lift Bail for K1524-1 Stand
K1556-1 Caster Kit for K1524-1 Stand
K1557-1 Swivel Platform for K1524-1 Stand
K377 Small Mounting Stand for Readi-Reel Coils and 22 to 30 lb Spindle with 2 in. O.D.
K378 Small Mounting Stand for 13 to 14 lb Innershield Coils
K435 Spindle Adapter for 14 lb Coils
K438 50 to 60 lb Readi-Reel Adapter
K445 Mounting Stand for Readi-Reel Coils and 50 to 60 lb Spindle with 2 in. O.D.
K468 Spindle Adapter for 8 in. O.D. Spools
M11514 Wire Reel Dust Shield Door for K303 and K376
S14543 Wire Reel Dust Shield for K376 50 to 60 lb Wire Reel Mounting Stand
LN-742 & LN-742H

C-2 ACCESSORIES C-2
K163 UNDERCARRIAGE K857 can be installed on the LN-742 when it is used

with newer Lincoln power sources that are equipped
The undercarriage includes casters, wheels, a handle, with a 6-socket ms-type receptacle or K864 14-pin
and related hardware. Casters are mounted at the front connector adaptor for connection of the plug on the 28
and wheels at the rear of the platform. The handle is ft (8.5 m) control cable of the K857. See the
bolted to the front of the platform so the wire feeder instructions (S19103) included with the kit.
can be tilted back and wheeled like a two-wheel truck.
Installation sheet M13424 is provided with the FLUX SYSTEM COMPONENTS
undercarriage.
The flux system is available to permit the LN-742 to be
K178-1 MOUNTING PLATFORM used for submerged arc welding. It is comprised of the
components described below.
This is a turntable type platform for mounting the LN-
742 to the top of Idealarc power sources. Bolt the K58 MAGNETIC SEPARATOR
platform to the lift bail per the instructions (M16260)
supplied with the platform. The K58 is a permanent magnet type separator
designed to fit the top of the standard fill funnel of the
K589-1 REMOTE continuous flux feeding system.
CONTROL KIT The purpose of the separator is to remove magnetic
materials such as mill scale and any other extraneous
Provides remote potentiometer control of weld speed magnetic materials which may have been recovered
and arc voltage up to 16.4 ft (5.0 m) from the wire along with the flux to be processed.
feeder. Power source must have remote control
capability. (K856 Power Source Remote Kit required It is important to remove these magnetic particles from
for CV-300/400-I, and smaller CV- Model machines the flux which is to be used in the continuous flux
below Code 9900.) Install K589-1 Kit per S20520 feeding systems. If the magnetic material is not
installation instructions provided with the kit. removed it will gather around the nozzle of the gun and
impede or shut off the flux flow when making relatively
K590-1 WATER long welds or welding continuously. The magnetic
SOLENOID KIT particles can also cause porosity in the weld.
Includes a solenoid valve already attached to a K310 FLUX SCREEN

mounting bracket and supply connection manifold
assembly for easy installation on the upper rear panel The unit was designed to fit the top of either the
of the LN-742 case. Also includes water-cooled gun standard fill funnel or a K58 magnetic separator. The
tube fittings and self-sealing outlet and inlet quick- unit has a steel screen with 0.065 to 0.075 in. openings
connectors for mounting to the front of the LN-742 and an air vibrator attached to the frame. The vibrator
case. can be used with air line pressures ranging from 20
through 100 psi.
K590-2 WATER For ease of handling, the user should connect the
CONNECTION KIT incoming air line to the 1/8 in. pipe elbow with the aid
of a quick disconnect type air coupling.
This kit is the same as the K590-1 except that it does
not include the solenoid for water coolers requiring It is very important that reclaimed flux to be used in the
continuous flow. continuous flux feeding system be passed through the
K310 screen or its equivalent.
K857 REMOTE VOLTAGE
CONTROL KIT
Installs on the side of the LN-742 control box cover and
gives voltage control at the wire feeder.
LN-742 & LN-742H

C-3 ACCESSORIES C-3
K320 FLUX TANK K593-10 INPUT CABLE AND

GAS HOSE
Either turn off the incoming air line or remove the quick
disconnect if one has been installed. Slightly loosen Similar to the K591, but includes a gas hose with a
the tank cap and let the air in the tank escape in the 5/8-18 male fitting for the LN-742 inlet, and water
holes in the side of the cap. After pressure has been hoses with 5/8-18 left-hand male fittings to connect
released, remove the cap from the tank. Using the between the water cooler and an LN-742 equipped
funnel provided, put 100 pounds of flux in the tank. It is with the optional K590-1 water solenoid kit. It is rated
very important that only new or properly reclaimed flux at 400 amps, 60% duty cycle, and is available in a 10
be put in the tank. Coarse particles and/or magnetic ft (3.0 m) length.
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
K619 INPUT CABLE
screen with 0.065 in. to 0.075 in. openings and be put
through a magnetic separator. The K310 vibrated Consists of an eight-conductor control cable with 14-
screen and K58 magnetic separator are available for pin control cable plug and a 1/0 (53 mm2) electrode
this purpose. The screen in the funnel supplied with the cable with stud terminals. It is rated at 350 amps, 60%
tank has much larger openings and its only purpose is duty cycle, and is available in lengths of 10, 25, and
to keep paper and slag out of the tank. 50 feet (3.0, 7.6, and 15.2 m).
There will always be a small amount of air and possible WELDING GUNS
drops of water coming out of the end of the tube coiled
under the tank. This is an automatic disposal system in GMAW GUNS
case the plant air has water and dirt in it.
An expanding line of Magnum GMA gun and cable
POWER INPUT CABLES assemblies are available to allow welding with solid
and cored electrodes using the GMAW process. See
A variety of power input cable assemblies are avail- the appropriate Magnum literature for descriptions of
able for various current ratings and power source con- the 200-400 ampere air cooled guns and cables that
nection types. All provide a polarized control cable are available. Gun cable lengths range from 10 to 25 ft.
plug and a lugged electrode cable for connection to (3.0 to 7.5 m) and feed electrode sizes 0.025 in. to 5/64
the wire feeder. in. (0.6 to 2.0 mm).
K591 INPUT CABLE
Consists of an eight-conductor control cable with 14-

pin control cable plug and a 2/0 (67 mm2) electrode
cable with Twist-MateTM connector. It is rated at 400
amps, 60% duty cycle, and is available in lengths of
10, 25, and 50 feet (3.0, 7.6, and 15.2 m).
K592 INPUT CABLE
Consists of an eight-conductor control cable with 14-

pin control cable plug and a 3/0 (85 mm2) electrode
cable with stud terminals. It is rated at 600 amps, 60%
duty cycle, and is available in lengths of 10, 25, and
50 feet (3.0, 7.6, and 15.2 m).
LN-742 & LN-742H

C-4 ACCESSORIES C-4
SPINDLES, STANDS, AND UNIVERSAL WIRE REEL STAND (K1524-1)

ADAPTERS Includes a 2" (51mm) O.D. Spindle with adjustable
brake and two locations for mounting the spindle to
There are a variety of spindles and wire reel adapters allow for the mounting of 50 - 60lb, 10 - 30 lb, 13 -
available for use with the LN-742. Select the desired 14lb, and 8" O.D. coils with proper spindle adapters.
setup according to your specific welding needs. (See OPERATION section) Capable of being mount-
ed on the top of a suitable power source or surface
K162H SPINDLE without the need for any other mounting kit. Optional
features available for this stand include:
The K162H spindle is used for mounting Readi-Reels • K1555-1 insulated lift bale
and 2 in. I.D. spools with a 60 lb capacity on a K303 or • K1556-1 caster kit
K376 Wire Reel Stand. When used with Readi-Reels, • K1557-1 swivel platform.
a Readi-Reel Adapter is required. For 8 in. O.D.
spools, a K468 Spindle Adapter is available. 60 LB. (27.2 KG) COIL ADAPTER (K1504-1)
Permits 50-60 lb. (22.7-27.2 Kg) coils to be mounted
K363P 22 TO 30 LB READI-REEL
to a 2" (51mm) spindle.
ADAPTER
Adapts Lincoln Readi-Reel coils of 22 and 33 lb (10

K1551-1 INSULATED LIFT BALE: Provides a
and 14 kg) to a 2 in. (51 mm) spindle. Durable, molded
bolt on lift bale with an electrically insulated lift hook.
plastic, one piece construction. Designed for easy
loading -- adapter remains on spindle for quick
changeover. (Included with K377.)
K1556-1 CASTER KIT: Comes with 4 light duty
2" O.D. casters which mount in place of the rubber
K376 AND K303 50 TO 60 LB WIRE REEL
feet on the wire stand. Use in light duty applications
MOUNTING STANDS where portability is required. Can be used in combi-
nation with the K1557-1 swivel platform.
The K376 50 to 60 lb Wire Reel Mounting Stand and
the K303 Wire Reel Mounting Stand are the same with
the exception that the K303 stand includes a dust K1557-1 SWIVEL PLATFORM: Allows for the
shield. The assembly includes a framework to which is mounting of the wire feeder reel stand assembly on
attached the 50 to 60 lb wire reel, a mounting spindle, top of a suitable power source if the need for the wire
a lift bale, and a cable clamp for fastening the input feeder reel stand assembly to swivel is desired. Also
cable assembly. It is easily mounted to the basic wire has mounting holes in the base feet for mounting to
feed unit by following the Attaching the Wire Reel any surface that it can be fastened to. Comes with a
Stand procedure at the end of this section. rotating tool tray to hold gun tips, guide tubes, drive
rolls, etc. Will work in combination with the K1556-1
caster kit.
LN-742 & LN-742H

C-5 ACCESSORIES C-5
K377 SMALL MOUNTING STAND FOR K468 SPINDLE ADAPTER FOR

READI-REEL COILS AND 22 TO 30 LB 8 IN. O.D. SPOOLS
SPINDLE WITH 2 IN. I.D.
Permits 8 in. (203 mm) O.D. spools to be mounted on
This assembly includes a wire reel spindle (similar to 2 in. (51 mm) O.D. spindles. For K377 and K445, or
the K162 spindle) attached to a small frame. The unit K303 and K376 with optional K162H adapter.
is supplied with the K363 Readi-Reel Adapter for using
the Lincoln “Readi-Reel Electrode Coils”. Without the M11514 WIRE REEL DUST SHIELD DOOR
adapter the unit is capable of handling spools with a FOR K303 AND K376
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 In extremely dusty and dirty locations this door kit can
available. The spindle has an adjustable braking be added to those units having the dust shield kit
system. See Attaching the Wire Reel Stand (S14543). This door kit includes a hinged door and
procedure at the end of this section for installation sliding bottom seal. When these parts are attached to
procedures. the reel support per the instructions included, the unit
becomes a completely enclosed housing. Order part
K378 SMALL MOUNTING STAND FOR no. M11514.
13 TO 14 LB INNERSHIELD COILS
S14543 WIRE REEL DUST SHIELD FOR
This assembly includes the same smaller frame as K376 50 TO 60 LB WIRE REEL MOUNTING
used in the K377 and the fully enclosed canister
STAND
system for dereeling of the 14 lb coil. This system has
a fixed brake for the 14 lb coil. See Attaching the Wire
Reel Stand Procedure at the end of this section for A shield is available to cover the wire and reel to
installation procedures. protect the wire from falling dirt and dust. Order part
no. S14543. Instructions are provided with the kit.
K435 SPINDLE ADAPTER FOR
14 LB COILS
ATTACHING THE WIRE
Permits 14 lb (6 kg) Innershield coils to be mounted on REEL STAND
2 in. (51 mm) O.D. spindles. For K377 and K445, or The mounting hardware for mounting the stands is
K303 and K376 with optional K162H adapter. included with the LN-742. Screws and washers are
inserted in their respective mounting holes. To
K438 50 TO 60 LB READI-REEL ADAPTER connect:
Adapts Lincoln Readi-Reel coils of 50 to 60 lb (22.7 to 1. Remove the three 3/8 in. hex head bolts from the
27.7 kg) to a 2 in. (51 mm) spindle. (Included with back of the wire feed unit.
K445.)
2. Place the wire reel mounting stand mounting
K445 MOUNTING STAND FOR READI- bracket in position against the back of the wire
REEL COILS AND 50 TO 60 LB SPINDLE feed unit.
WITH 2 IN. O.D.
3. Replace and tighten the hex head bolts. The long
screw and plain washer go into the top hole.
50 to 60 lb (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 lb (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 S14543. This unit will accept the
M11514 door kit (see K303) but only if already
equipped with optional dust shield (S14543).
LN-742 & LN-742H

C-6 ACCESSORIES C-6
DRIVE ROLL KITS

Table C-2 lists the appropriate drive roll kits for each
type of wire used.
TABLE C.2 – DRIVE ROLL KIT NUMBERS.
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. (1.2-1.3 mm) Cored KP653-052C KP655-052C
0.035 in. (0.9 mm) Solid KP653-035S KP655-035S
0.035 in. (0.9 mm) Cored KP653-035C KP655-035C
0.030 in. (0.8 mm) Solid KP653-030S KP655-030S
0.023-0.025 in. (0.6 mm) Solid KP653-025S KP655-025S
Aluminum Wire Sizes*
1/16 in. (1.6 mm) KP688-1/16A KP647-1/16A
3/64 in. (1.2 mm) KP688-3/64A KP647-3/64A
0.035 in. (0.9 mm) KP688-040A KP647-040A
* For use with Binzel European Guns L9933 Installation instructions are included.
** Not for use with, LN-742H model.
LN-742 & LN-742H

D-1 MAINTENANCE D-1
ROUTINE MAINTENANCE No routine maintenance is required for Readi-Reels

and 10 to 30 lb spools. Do not lubricate the 2 in.
spindles.
DRIVE ROLLS AND GUIDE TUBES
After feeding every coil of wire, inspect the drive roll PERIODIC MAINTENANCE
section. Clean the assembly as necessary. Do not use
solvent to clean the drive roll assembly as it may wash WIRE DRIVE MOTOR AND GEARBOX
the lubricant out of the bearings. The drive rolls and
guide tubes are stamped with the wire sizes they will Every year inspect the gearbox and coat the gear
feed. If a wire size other than that stamped on the rolls teeth with a moly-disulfide filled grease. Do not use
is to be used, the rolls and guide tubes must be graphite grease.
changed.
Every six months check the motor brushes. Replace
The drive rolls for 0.045 and 0.052 cored electrode them if they are less than 1/4 in. long.
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 GUN AND CABLE MAINTENANCE
additional life. Drive rolls for 0.023 through 0.052 solid
electrodes have no teeth. For instructions on periodic maintenance for the
welding gun and cables, refer to the instructions
Refer to the instructions in Section B, Operation for included with your specific model of welding gun.
installation of drive rolls.
WIRE REEL MOUNTING
To prolong the life of the reel shaft on the 50 to 60 lb

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.
LN-742 & LN-742H

E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. 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 three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Step 3. RECOMMENDED COURSE OF

Look under the column labeled “PROBLEM ACTION
(SYMPTOMS)”. This column describes This column provides a course of action for
possible symptoms that the machine may the Possible Cause, generally it states to
exhibit. Find the listing that best describes contact you local Lincoln Authorized Field
the symptom that the machine is exhibiting. Service Facility.
Step 2. POSSIBLE CAUSE. If you do not understand or are unable to

The second column labeled “POSSIBLE perform the Recommended Course of
CAUSE” lists the obvious external possibili- Action safely, contact you local Lincoln
ties that may contribute to the machine Authorized Field Service Facility.
symptom.
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 & LN-742H

Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
The display is blank. No wire feed 1. Make sure the control cable is
when the gun trigger is activated. connected to the welding power
source correctly.
2. Make sure the welding power

source is turned on and func-
tioning properly.
3. Check the 42 VAC fuse or cir-

cuit breaker in the welding
power source.
If all recommended possible areas of

misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
No wire feed when the gun trigger 1. Check or replace the gun trigger Field Service Facility.
is activated. The solenoid does not switch.
function. No arc voltage present.
The display board indicates the 2. Check the gun trigger recepta-
LN-742 has input power applied. cle. Check for loose or faulty
connections.
CAUTION
LN-742 & LN-742H
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-
sent at the welder output termi-
nals. If no voltage is present at
the output terminals the power
source is faulty.
2. The control cable may be faulty.

Check leads #2 and #4 (pins C
and D) for continuity (zero
ohms).
3. The welding cables may me

faulty. Check for loose or faulty
connections.
4. The gun may be faulty. Check

or replace.
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 connections 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 may
change when welding current be set to the same value.
begins to flow.
2. If the display shows the ----
symbol the inch speed has
been disabled. To enable the
inch speed press the increase
arrow key.
3. Check plug J2 on the control

board for loose or faulty con-
nections.
CAUTION
LN-742 & LN-742H
The LN-742 voltmeter does not 1. Make sure the polarity switch on
function or read correctly when the the Lincoln welding power
actual arc voltage is present. The source is in the correct position
wire feeder is feeding wire correct- for the welding process.
ly.
2. Check or replace the control
cable. Check the continuity
(zero ohms) of leads #21 and
#67.
The LN-742 shuts down while 1. Check for mechanical restric-

welding and the HXX symbol tions in the wire feed path.
appears on the display. If all recommended possible areas of
your local Lincoln Authorized
Field Service Facility.
The display and/or indicator lights 1. Make sure the control cable is
do not change when the arrow or connected to the welding power
select keys are pressed. source correctly.
2. Check the 42 VAC fuse or cir-

cuit breaker in the welding
power source.
The arrow keys do not change the 1. If a remote control unit is con-
welding wire feed speed. 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
LN-742 & LN-742H
The purge key does not activate 1. Contact your local Lincoln
the gas solenoid. The solenoid Authorized Field Service
does activate when the gun trigger Facility.
is pulled.
The gas solenoid does not activate 1. Check plug J6, located on the
either when the purge key is control board for loose or faulty
pressed or when the gun trigger is connections.
pulled.
The cold inch key does not activate 1. Contact your local Lincoln
the wire feed motor. The wire feed Authorized Field Service
motor operates normally when the Facility.
gun trigger is pulled.
The HI symbol appears on the dis- 1. If the arc voltage is greater than
play when the voltmeter function is 44 VDC, this is a normal condi-
selected. tion. The voltmeter only reads
0-44 VDC.
The Er symbol appears on the dis- 1. This is an EPROM error. The misadjustment have been checked
play. parameter recalled at power-up and the problem persists, Contact
is out of range. Press any key your local Lincoln Authorized
to reset unit. Check all weld Field Service Facility.
settings before proceeding with
weld.
The EXX appears on the display. 1. Remove input power to the

(XX is some number from 1 to 10.) feeder (42 VAC). Wait 5 sec-
onds. The symbol should not
reappear when power is
returned.
The EP symbol appears on the 1. Remove input power to the

display. feeder (42 VAC). Wait 5 sec-
returned.
The uP symbol appears on the dis- 1. Remove input power to the

play. (Microprocessor RAM error.) feeder (42 VAC). Wait 5 sec-
returned.
CAUTION
LN-742 & LN-742H
The wire is feeding rough or not 1. Check for mechanical restric-
feeding. The drive rolls are turn- tions in the wire feeding path.
ing. Check the gun and gun compo-
nents.
2. Check the drive roll position and

idle roll pressure.
3. The electrode may be dirty or

rusty.
4. Check for the correct gun liner,

tip, and guide tubes. If all recommended possible areas of
The drive rolls do not turn when the 1. Check plug J5 on the control your local Lincoln Authorized
gun trigger is pressed. The gas board for loose or faulty con- Field Service Facility.
solenoid activates and arc voltage nections.
is present.
CAUTION
LN-742 & LN-742H
The welding arc is variable or 1. Check the welding cables for
“hunting”. loose or faulty connections.
2. Make sure the wire feed speed,

voltage, polarity and shielding
gas are correct for the process
being used.
3. Check for mechanical restric-

tions in the wire feed path.

source is functioning properly. If all recommended possible areas of
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.

source is functioning properly.
3. Make certain the gas solenoid is

operating properly and the gas
flow rate is correct for the pro-
cedure.
4. The welding gun may be faulty.

Check for gas leaks or replace
gun.
CAUTION
LN-742 & LN-742H
F-1
WIRING DIAGRAM LN-742

CURRENT
SENSING
INPUT ELECTRODE CABLE
REED SWITCH
551
552
553
500
554
512A
OPTIONAL
WATER
1 2 3 4 5 6 7 8
SOLENOID B
P.M. W 67
*
TACH J11
GAS
SOLENOID R U B
DISPLAY
R.F. TOROID ASSEMBLY
R U B
P.C. BOARD
500 C D A B E G F
1 2 3 4 5 6 7 8
N.A. J10 *
542
553
551
552
554
2
21
4
500
512A
67
W
500M
518
516
517
542
4
4
U U R U B B W
BRIDGE +
AC AC R
- 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 1 2 KEYPAD
R
500M
*
500
*
*
*
*
J2 J3 J4 J5 J6 J7
1 2 3 4 5 6 7 8 9 1 0 1 11 2 B
A
A
*
J1 B
C
R.F. TOROID ASSEMBLY
C
D
D
E
E
INPUT CABLE
RECEPTACLE
F G
41 A
DIAGRAMS
LN-742 & LN-742H

R
F
42 B R
G
C 2
D 4
J12 E 21
CONTROL P.C. BOARD P8
F 75
***
W 1 A
G 76
H 77 B GUN
W 2 C J14 CONTROL
D CABLE R
L E W 10K
CW
R.F. CHOKE
ELECTRICAL SYMBOLS PER E1537. B VOLTAGE
W.F.S. POT. CONNECTOR AND N
* CAVITY NUMBERING SEQUENCE PIN NUMBERING SEQUENCE VOLTAGE POT. CONNECTOR
(COMPONENT SIDE OF P.C. BOARD)
** (COMPONENT SIDE OF P.C. BOARD) N.A. PRESENT ONLY ON THE LN-742H MODELS. U 5K
CW
L L
1 6 12 8 LEAD COLOR CODING 518 1 518 A N G W.F.S.
J10 1 L L
J2 B - BLACK 517 2 517 B U
J1 J11 L L
J3 R - RED 516 3 516 C G
7 12 L
3 4 W - WHITE 75 4 75 D B
L OPTIONAL REMOTE
1 1 CONNECTOR CAVITY U - BLUE 76 5 76 E W
4 3 1 L
J6 *** NUMBERING SEQUENCE G - GREEN 77 6 77 F R WIRE FEED SPEED &
J5
J4 J7 VOLTAGE POT. ASSEMBLY
J9 (NON LEAD SIDE OF CONNECTOR) N - BROWN J13
J8
5 8 4 6 2 4
1 6
P10
P9
P8 P9 ***
P11
2 3 1
PIN 1
R 3-29-96H
L9124
CLEVELAND, OHIO U.S.A.
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 code number..
F-1
NOTES
LN-742 & LN-742H

Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
since 1933, the Procedure Handbook is considered by many to such as distortion; and supplemental information on arc
be the “Bible” of the arc welding industry. welding applications, speeds and costs. Practice materials,
This printing will go fast so don’t delay. Place your exercises, questions and answers are suggested for each
order now using the coupon below. lesson.
The hardbound book contains over 750 pages of welding 528 pages, well illustrated, 6” x 9” size, bound in simulated,
information, techniques and procedures. Much of this material gold embossed leather.
has never been included in any other book. $5.00 postage paid U.S.A. Mainland
A must for all welders, supervisors, engineers and

designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
How To Read Shop Drawings most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 stu-
dents have graduated. Tuition is low and the training is
The book contains the latest information and application
“hands on”
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and For details write: Lincoln Welding School
draftsmen use the “short-cut” language of symbols to pass 22801 St. Clair Ave.
on assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear Welding School Registrar.
in their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2” x 11” Lincoln Welding School
Durable, cloth-covered board binding. BASIC COURSE $700.00
$4.50 postage paid U.S.A. Mainland 5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
$10.00 For order value between $50.00 & $99.99
$15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders) Name: _______________________________________________
CHECK ONE:
Address: _______________________________________________
Please Invoice (only if order is over $50.00)
Check or Money Order Enclosed, U.S. Funds only _______________________________________________
Credit Card - VISA MasterCard
®
Telephone: _______________________________________________
®
Signature as it appears on Charge Card:

Account No. |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|
MasterCard
AMERICAN EXPRESS
Exp Date |_|_|
Month
|_|_|
Year ______________________
AMERICAN EXPRESS
USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
NOTES
LN-742 & LN-742H

NOTES
LN-742 & LN-742H

● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION ● Aislese del trabajo y de la tierra.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• 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

LN-742 & LN-742H Wire Feeders: Operator'S Manual

Uploaded by

Copyright:

Available Formats

LN-742 & LN-742H Wire Feeders: Operator'S Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

LN-742 & LN-742H Wire Feeders: Operator'S Manual

Uploaded by

Copyright:

Available Formats

IM502-A

LN-742 & LN-742H Wire Feeders June, 2000

For use with machines having Code Numbers: 10029

• World's Leader in Welding and Cutting Products •

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

5.e. Also see item 1.b.

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

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

for selecting a QUALITY product by Lincoln Electric. We want you

Please Examine Carton and Equipment For Damage Immediately

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

LN-742 & LN-742H

TECHNICAL SPECIFICATIONS – LN-742

WIRE FEED SPEED

TEMPERATURE RATING (ALL MODELS)

ENVIRONMENTAL RATING (ALL MODELS)

LN-742 & LN-742H

For connecting an LN-742 to a specific Lincoln power

LN-742 & LN-742H

5. Referring to Figure A.2, install the input cable

Pins not listed in the table in Figure A.3 are not

LN-742 & LN-742H

WARNING TURN INPUT POWER OFF

C=2 H=21 H=21 C=2

D=4 G=75 G=75 D=4

E=77 F=76 F=76 E=77

PIN LEAD FUNCTION

CLEVELAND, OHIO U.S.A

LN-742 & LN-742H

TABLE A.1 – WORK LEAD SPECIFICATIONS

Copper Work Cable Size, AWG

GUN AND CABLE ASSEMBLIES

An expanding line of Magnum X-Tractor gun and cable

* Requires S14927-8 connector hose and an S20591 hose adapter.

LN-742 & LN-742H

WATER CONNECTIONS 1. Using male 5/8-18 UNF left-hand thread fittings,

LN-742 & LN-742H

FIGURE A.5 – SHIELDING GAS HOOKUP.

LN-742 & LN-742H

OPERATING INSTRUCTIONS GENERAL DESCRIPTION

• Wire feed control [50 to 770 in./min (1.25 to 19.5

LN-742 & LN-742H

FIGURE B.1 – WIRE FEEDER CONTROLS.

TRIGGER MODE TIME

LN-742 & LN-742H

FUNCTION SELECTION CONTROLS. This control ENGLISH OR METRIC SPEED

ACCELERATION SETTING DRIVE ROLL INSTALLATION

3. Remove the hex head screw and clamping collar.

4. The new roll to be installed is stamped for the size

LN-742 & LN-742H

FIGURE B.2 – INSTALLING DRIVE ROLLS ON A TWO-ROLL FEEDER.

SPACER (IF REQUIRED)

GUIDE TUBE DETAIL LARGE

LN-742 & LN-742H

LN-742 & LN-742H

FIGURE B.3 – INSTALLING DRIVE ROLLS ON A FOUR-ROLL FEEDER.

GUIDE TUBE DETAIL LARGE

LN-742 & LN-742H