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TROUBLE SHOOTING

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).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This
column describes possible symptoms that the machine may exhibit.
Find the listing that best describes the symptom that the machine is
exhibiting.

Step 2.

POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.

Step 3.

RECOMMENDED COURSE OF
ACTION

This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln Authorized Field
Service Facility.

If you do not understand or are unable to perform the Recommended
Course of Action safely, contact your local Lincoln Authorized Field
Service Facility.

FLEX FEED™ 74 HT

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in
danger to the technician and machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical Shock, please observe all safety
notes and precautions detailed throughout this manual.

WARNING

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Содержание FLEX FEED 74 HT

Страница 1: ...egistration Authorized Service and Distributor Locator www lincolnelectric com locator IM10163 Issue Date Nov 13 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12039 12052 Save for future reference Date Purchased Code ex 10859 Serial ex U1060512345 ...

Страница 2: ...the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helm...

Страница 3: ...ty guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete ...

Страница 4: ...o ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes and g...

Страница 5: ...les or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 6 j Do not use a welding power source for pipe thawing CYLINDER MAY EXPLODE IF DAMAGED 7 a...

Страница 6: ...ions B 2 Equipment Limitations B 2 Recommended Power Sources B 2 Front and Side View B 3 Rear View B 4 Wire Feed Speed Knob B 5 Remote Voltage Control Knob B 5 2 Step Trigger Interloock Switch B 5 Thermal LED B 5 Cold Feed B 5 Gas Purge B 5 Digital Meters B 5 Timer Kit B 5 Power Up Sequence B 6 User Interface B 6 Gouging Kit B 7 Accessories Section C Optional Kits and Accessories C 1 Gun Adapter K...

Страница 7: ...tage drop GENERAL FUNCTIONAL DESCRIPTION The base model Flex Feed 74 HT has knobs for wire feed speed and remote voltage control A large rocker switch on the side of the feeder allows for activation of Cold Feed and Gas Purge 2 step Trigger Interlock offers operator comfort when making long welds Two wire feed speed ranges are available dependent upon the pinion gear installed in the wire drive Th...

Страница 8: ... No Gouging Kit With Gouging Kit Wire Drive Wire Drive Gouging Stud DUTY CYCLE 60 60 30 INPUT AMPERES 600 Amps 500 Amps 600 Amps GEARING WIRE FEED SPEED RANGE WIRE SIZE WFS RANGE 50 500 inch min 1 3 12 7 m min 50 700 inch min 1 3 19 0 m min 025 3 32 0 6 2 4 mm 025 1 16 0 9 1 6 mm 035 120 0 9 3 0 mm 035 5 64 0 9 2 0 mm PINION GEAR 20 tooth 30 tooth GMAW FCAW Thermal tests have been performed at amb...

Страница 9: ...c Advanced Basic Advanced Advanced Advanced Basic Advanced Basic Advanced Basic Basic Basic Wire Reel Stand Standard Duty Standard Duty Standard Duty Standard Duty Standard Duty Standard Duty Heavy Duty Heavy Duty Heavy Duty Heavy Duty Heavy Duty Heavy Duty Heavy Duty Gun 300A 035 045 400A 052 1 16 300A 035 045 400A 052 1 16 K126 PRO Gouging Kit Yes Yes Yes Yes Yes Yes Yes Yes Yes MODEL NUMBERS FO...

Страница 10: ...ice is use it must be insulated from the wire feeder enclosure MOVING PARTS can injure Keep away from moving parts WARNING LOCATION The Flex Feed 74 HT is rated IP2X and is suitable for indoor use For best wire feeding performance place the Flex Feed 74 HT on a stable and dry surface When suspending the wire feeder insulate the hanging device from the wire feeder enclosure DRIVE ROLL AND WIRE GUID...

Страница 11: ...he gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds 2 If the wire birdnests or jams the drive roll pressure is too high Reduce the pressure by one turn of the knob run new wire through the gun and repeat step 1 3 If the only result is slippage disconnect the gun and pull the gun cable forward about 6 150mm There should be...

Страница 12: ...ER REPLACEMENT PROCEDURE 1 Turn power OFF at the welding power source 2 Using a Phillips screw driver loosen the screw securing the gun adapter cover Remove the gun adapter cover 3 With a 3 4 wrench remove the bolt holding the electrode lead to the gun adapter SCREW GUN ADAPTER COVER ELECTRODE LEAD BOLT FIGURE A 3 FIGURE A 4 ...

Страница 13: ...A 6 INSTALLATION FLEX FEED 74 HT 4 Use a 1 8 hex key to loosen the set screw securing the gun adapter SET SCREW GUN ADAPTER FIGURE A 5 ...

Страница 14: ...hose clamp and remove the gas hose 7 If the gun adapter requires guide tubes install the correct size guide tube and secure with the set screw Wire size Number of grooves in guide tube 023 045 0 6 1 2mm 1 045 1 16 1 2 1 6 mm 2 1 16 5 64 1 6 2 0 mm 3 068 7 64 2 0 2 8 mm 4 120 3 0 mm No Guide Tube Required SENSE LEAD SET SCREW GUIDE TUBE FIGURE A 6 FIGURE A 7 ...

Страница 15: ...ing on the feed plate and secure with a hose clamp 10 Assemble the gun adapter to the wire drive Tighten the set screw once the gun adapter is at a 90 angle 11 Bolt the electrode lead to the gun adapter making sure to route the lead straight down FIGURE A 8 12 Assemble the gun adapter cover and secure with the screw FIGURE A 9 SCREW GUN ADAPTER COVER KEEP TERMINAL AND LEAD VERTICAL ELECTRODE LEAD ...

Страница 16: ...n adapter to be installed in the wire drive 1 Turn power OFF at the welding power source 2 Using a Phillips screw driver loosen the screw securing the gun adapter cover Remove the gun adapter cover 3 With a 3 4 wrench remove the bolt holding the electrode lead to the gun adapter SCREW GUN ADAPTER COVER ELECTRODE LEAD BOLT FIGURE A 10 FIGURE A 11 ...

Страница 17: ...D 74 HT 4 Using pliers remove the hose clamp and hose from the gun adapter 5 Bolt the electrode lead to the gun adapter making sure to route the lead straight down KEEP TERMINAL AND LEAD VERTICAL ELECTRODE LEAD BOLT FIGURE A 12 ...

Страница 18: ... the set screw Wire size Number of grooves in guide tube 023 045 0 6 1 2mm 1 045 1 16 1 2 1 6 mm 2 1 16 5 64 1 6 2 0 mm 3 068 7 64 2 0 2 8 mm 4 9 Slide the Oxo or FastMate gun adapter into the wire drive and secure with the thumb screw 10 For FastMate gun adapters connect the trigger pigtail to the connector on the front of the feeder SCREW GUN ADAPTER COVER SET SCREW GUIDE TUBE FIGURE A 13 FIGURE...

Страница 19: ...desired the 30 tooth pinion gear may be installed for more speed but less torque 1 Turn power OFF at the welding power source 2 Open the wire drive door and loosen the set screw holding the hinge pin using a 5 64 hex key Slide the hinge pin towards the rear and remove the door HINGE PIN SET SCREW FIGURE A 15 FIGURE A 16 ...

Страница 20: ...have pink terminals cable tied into a bundle close to the pc board 20 tooth pinion gear connect 586 to 515E 30 tooth pinion gear disconnect 586 to 515E 10 Apply remove the wire feed speed decal from the name plate as follows Speed Range Decal 50 500 in min Default value Remove any decals applied to the nameplate 50 700 in min M24808 1 1 5 12 5 m min M24808 2 1 5 18 m min M24808 3 Decals are locate...

Страница 21: ...w driver loosen the screw securing the gun adapter cover Remove the gun adapter cover FIGURE A 19 3 With a 3 4 wrench remove the bolt holding the electrode lead to the gun adapter FIGURE A 20 4 Use a 1 8 hex key to loosen the set screw securing the gun adapter FIGURE A 21 5 Remove the sense lead with a Phillips screw driver FIGURE A 22 6 If a gas hose is attached to the gun adapter use pliers to r...

Страница 22: ...d leads connected to the gas solenoid Remove the plug button from the rear opposite the gas solenoid FIGURE A 25 10 Remove the upper motor support Use a 5 16 nut driver to remove the 2 screws at the rear and the 2 screws at the front Use a 3 8 wrench to remove the 3 screws holding the support to the gearbox FIGURE A 26 11 Remove the 4 screws holding the motor gearbox assembly to the case and lift ...

Страница 23: ...ad positions by using a 11 16 wrench b Swap the leads to the contactor coils Lead 549A attaches to the wire drive contactor Lead 549B attaches to the gouging stud contactor Lead 552 is common to both contactors 13 Change the polarity of the motor leads by swapping the large black and white leads in the motor harness plug SPACERS PLAIN WASHER INSULATOR BUSHING CURRENT TRANSDUCER WIRE DRIVE LEAD LOC...

Страница 24: ... the upper motor support with plastic washers on the appropriate side 16 To move the Cold Feed Gas Purge rocker switch from the right side to the left side remove the leads from the switch Squeeze the snaps holding the switch to the sheet metal and push the switch outwards Reassemble the switch on the left side 559 559 515 515C FIGURE A 30 FIGURE A 31 ...

Страница 25: ...side 18 Remove the 4 screws holding the user interface to gain access to the inside front compartment of the feeder 19 Move the thermal LED from right to the left hand side Gently pull on the black body of the LED holder to separate it from the clear lens FIGURE A 33 FIGURE A 32 522 552F 515E 515G 515F ...

Страница 26: ... the rear of the feeder 22 Reassemble the case sides and roof to the feeder taking care to route the gas line and electrode sense lead through the case side opening by the rear of the motor gearbox 23 Reassemble the feed plate to the gear box and secure by tightening the socket head cap screw PLUG BUTTON 5 PIN TRIGGER CONNECTOR 67 ELECTRODE SENSE LEAD GAS HOSE SOCKET HEAD CAP SCREW FIGURE A 34 FIG...

Страница 27: ...door insert b Remove the 2 socket head cap screws c Fully unscrew the pressure knob and slide the washers and rod out of the door a DOOR INSERT AND SCREW b SOCKET HEAD CAP SCREW SOCKET HEAD CAP SCREW SCREWS INTO THIS INDICATOR c PRESSURE KNOB AND ROD PRESSURE ARMS RIGHT HAND ASSEMBLY FIGURE A 37 ...

Страница 28: ...Assemble the socket head cap screws and indicator tightening the indicator screw to a height of 27 and the other screw to 34 d Assemble the washers and pressure knob e Assemble the door insert e DOOR INSERT AND SCREW c SOCKET HEAD CAP SCREW SPRINGS SOCKET HEAD CAP SCREW SCREWS INTO THIS INDICATOR b SLIDE ROD THROUGH SPRINGS a PRESSURE ARMS d WASHERS WITH PRESSURE KNOB LEFT HAND ASSEMBLY c 27 c 34 ...

Страница 29: ...adapter The bolt for the wire drive lead will align the gun adapter with the feed plate as the bolt is tightened The terminal of the lead must be in a vertical position 27 Tighten the set screw to secure the gun adapter in place 28 Secure the G7644 1 gun adapter cover in place with the Phillips screw lockwasher and plain washer TERMINAL OF LEAD MUST BE VERTICAL FIGURE A 39 FIGURE A 40 PHILLIPS SCR...

Страница 30: ...neath the wire drive 1 Turn power OFF at the welding power source 2 Install the quick disconnect fittings to the plastic bracket by holding the rear nut stationary and spinning the fitting 3 Cut the tubing to the desired length and then install the tubing and hose clamps to the fittings FIGURE A 41 ...

Страница 31: ...NT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet 4 Attach the flow regulator to the cylinder valve and tight en the union nut s securely with a wrench Note if connecting to...

Страница 32: ...en threading wire or changing wire spool Only qualified personnel should install use or service this equipment 50 60 lb 22 27 kg coils require K3343 1 Heavy Duty Wire Reel Stand 1 Turn power OFF at the welding power source 2 Squeeze the release bar on the retaining collar and remove it from the spindle WARNING SQUEEZE RELEASE BAR FIGURE A 42 ...

Страница 33: ...An indicator mark on the end of the spindle shows the orientation of the brake holding pin Be certain the wire feeds off of the spool in the proper direction 4 Re install the retaining collar with the metal bar engaging one of the grooves of the spindle The release bar will spring out when engaged FIGURE A 43 ALIGN BRAKE PIN WITH HOLE INDICATOR MARK ...

Страница 34: ... FLEX FEED 74 HT WIRE REEL STANDS K3342 1 Standard Duty Wire Reel Stand is for use with spools 10 to 44 lb 4 5 to 20 kg When using the K3343 1 Heavy Duty Wire Reel place the spindle in the location as shown FIGURE A 44 ...

Страница 35: ...ction is no more than 15 amps Do not use more than 300 ft 30 5 m of control cable between the wire feeder and power source Pin Function Lead A B C Welding Output Control trigger to power source 2 D Welding Output Control trigger to power source 4 E Remote Voltage Control supply from power source 77 F Remote Voltage Control control signal from feeder or remote 76 G Remote Voltage Control supply fro...

Страница 36: ...le below for proper opera tion of the wire feeder Be sure the power source pro vides 24 VAC to the wire feeder and has overcurrent protection of no more than 15 amps The power source must not exceed 113VDC peak Operation of Lincoln wire feeders on 24 VAC may result in lack of high wire feed speeds or reduced pull force at high wire feed speeds Approximate maxi mum WFS for Lincoln wire feeders oper...

Страница 37: ...480 VAC 3 amps 28 VDC To make connections to the relay 1 Turn power OFF at the welding power supply 2 Remove the 4 screws securing the roof with a 5 16 nut driver 3 Remove the 4 screw securing the User Interface with a 5 16 nut driver 4 Remove the plastic plug button at the rear of the feeder and replace with an appropriate electrical bushing Route the wires through the bushing to the relay 5 Reas...

Страница 38: ...AW PROCESS CARBON ARC GOUGING PROCESS CONTACTOR COLD FEED GAS PURGE SHIELDING GAS INLET SHIELDING GAS OUTLET PREFLOW t BURNBACK 2 POSTFLOW 2 STEP TRIGGER TRIGGER INTER LOCK THREMAL WELDING AMPERAGE WELDING VOLTAGE POSITIVE OUTPUT NEGATIVE OUTPUT INPUT POWER INPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION U1 I1 I2 A ...

Страница 39: ...AG with gouging option installed PROCESS LIMITATIONS Processes must be within the duty cycle and rating of the wire feeder EQUIPMENT LIMITATIONS Does not include weld cables Operates on 24 42 VAC input Must use newer gun adapter kits Not compatible with K1500 1 K1500 2 K1500 3 K1500 4 K1500 5 and K489 7 gun adapter kits RECOMMENDED POWER SOURCES Power Source Flextec 450 Flextec 650 V 350 CV 305 CV...

Страница 40: ...RFACE SHOWN SIDE VIEW See Figure B 2 VOLTS DISPLAY AMPS DISPLAY PREFLOW BURNBACK POSTFLOW TRIGGER CONNECTOR 5 PIN 2 STEP TRIGGER INTERLOCK SWITCH REMOTE VOLTAGE CONTROL KNOB WIRE FEED SPEED KNOB FIGURE B 1 COLD FEED GAS PURGE SWITCH THERMAL LED PRESSURE ADJUST KNOB FIGURE B 2 ...

Страница 41: ...B 4 OPERATION FLEX FEED 74 HT REAR VIEW See Figure B 3 SHIELDING GAS INLET CONTROL CABLE WITH 14 PIN CINNECTOR ELECTRODE CONNECTION COVER NOT SHOWN FOR CLARITY ...

Страница 42: ...eld is made To stop welding the gun trigger is pulled again and when it is released the welding power source output turns off and the wire feeder stops feeding wire If the arc goes out while welding with trigger interlock operation the electrode output from the welding power source remains energized and the wire feeder will continue to feed wire until the gun trigger is again pulled and then relea...

Страница 43: ...uminates for 2 seconds 2 If the trigger is already activated the thermal LED will quickly blink until the trigger is released USER INTERFACE User Interface Layout Advanced User Interface Layout Basic FLEX FEED 74 HT LED LOCATION LED LOCATION FIGURE B 4 FIGURE B 5 FIGURE B 6 A V ...

Страница 44: ...uging operation With the switch in the weld position the Flex Feed 74 HT functions normally and the output connection for the gouging torch is OFF With the switch in the gouge position the power source output and gouging connection are ON and the welding gun is OFF Do Not Switch processes while actively welding or gouging WARNING FIGURE B 7 WIRE FEED GOUGING ROCKER SWITCH GOUGING STUD COVER NOT SH...

Страница 45: ... 1 16 1 6mm Includes 4 Knurled drive rolls and inner wire guide Drive Roll Kits Steel or Cored Wires KP1505 068 068 072 1 8mm KP1505 5 64 5 64 2 0mm KP1505 3 32 3 32 2 4mm KP1505 7 64 7 64 2 8mm KP1505 120 120 3 2mm Includes 4 Knurled drive rolls and inner wire guide Drive Roll Kits Hardfacing Wires KP1505 7 64C 7 64 2 8mm Includes 2 Knurled drive rolls 2 Smooth V groove drive rolls and inner wire...

Страница 46: ...Gun Adapter Kit Lincoln Back end K3345 1 Gun Adapter Kit standard 4 back end K3346 1 Gun Adapter Kit Magnum 500 5 back end K3347 1 Gun Adapter Kit Miller back end K3348 1 Gun Adapter Kit Oxo back end requires K3345 1 K3349 1 Gun Adapter Kit Fast Mate Euro requires K3345 1 ...

Страница 47: ... 14 pin cable the wire drive for boom systems Connects the wire drive to the power source on bench systems K2335 1 2 Competitive Equipment Adapter Used to connect the Flex Feed 74 HT to power sources with 24 VAC K1798 Adapter Cable Female 14 pin Connects the control cable to to Terminal Strip older power sources that only have terminal strips ...

Страница 48: ...onduit K1546 2 Incoming Bushing Use with 1 16 to 1 8 wires for Lincoln Conduit K3929 1 Inlet Bushing quick connect style Included with Flex Feed 74 HT feeders without a wire reel stand K1733 1 Wire Straightener K1504 1 50 60 lb coil adapter for For use with K3343 1 2 inch spindles heavy duty wire reel stand K590 6 Water Connection Kit Includes 4 female quick disconnects tubing and clamps water coo...

Страница 49: ...ndard Duty Wire For spools up to 44 lbs Reel Stand K3343 1 Heavy Duty Wire Reel Stand For spools up to 44 lbs and coils up to 60 lbs Includes K3341 1 Lift Bail K3341 1 Lift Bail Insulated lift bail for suspending the wire feeder Requires either standard duty or heavy duty wire reel stand K3342 1 Standard Duty Wire For use with 30 40 lb spools Reel Stand K3343 1 Heavy Duty Wire For use with 50 60 l...

Страница 50: ...source 2 Remove the 4 screws holding the roof of the wire feeder to gain access to the pc board 3 Turn power ON and trigger the Flex Feed 74 HT 4 Set the WFS knob to 50 in min and measure the drive roll rpm If the drive roll rpm measures 8 9 to 9 2 rpm proceed to step 7 5 Unplug the connector in J2 Insert a shorting plug that shorts pin 1 and 5 Adjust the WFS knob as required until drive roll rpm ...

Страница 51: ...tact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility FLEX FEED 74 HT 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 ...

Страница 52: ...tact tip is partially melted or has spatter 6 Improper gun liner tip drive rolls and or inner wire guide 7 Incorrect pressure on the drive rolls 8 The spindle brake is too tight 9 Worn drive roll 1 Turn ON the power source 2 Reset the circuit breakers 3 Tighten repair or replace the con trol cable 1 Verify the gas supply is ON and flowing 2 Route the gas hose so it avoids sharp corners and make su...

Страница 53: ...rn and or melted contact tip 2 Worn work cable or poor work connection 3 Wrong polarity 4 The gas nozzle is extended beyond the contact tip or the wire stickout is too long 5 Poor gas shielding on processes requiring gas 1 If a gouging kit is installed the gouging switch is in the gouge position 2 If a gouging kit in installed verify there is continuity from the elec trode input to the wire drive ...

Страница 54: ... 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 ...

Страница 55: ... WIRE DRIVE HOUSING 13 28 34 11 57 2 00 2 00 3 28 1 50 3 78 1 50 76 1 70 8 19 5 16 18 UNC 2B 8 PLACES 8 80 57 9 94 11 58 18 04 11 02 10 12 10 67 2 30 12 39 1 03 2 25 3 40 2 99 6 00 75 9 00 1 76 5 16 18 UNC 2B 4 PLACES 4 75 1 4 20 UNC 2B 4 PLACES 13 57 ...

Страница 56: ...F 3 DIAGRAMS FLEX FEED 74 HT DIMENSION DRAWING FOR STANDARD DUTY WIRE REEL STAND 21 67 23 62 14 08 7 79 10 01 13 28 15 46 11 00 ...

Страница 57: ...F 4 DIAGRAMS FLEX FEED 74 HT 12 18 24 45 14 33 16 42 27 93 12 71 DIMENSION DRAWING FOR HEAVY DUTY WIRE REEL STAND 15 46 11 00 25 17 10 56 5 94 8 36 9 06 50 ...

Страница 58: ...FLEX FEED 74 HT NOTES ...

Страница 59: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufactur...

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