Lincoln Electric LWF-4GS User manual

IM7203-1
November, 2016
Rev. 02
LWF -4GS Wire Feeder
Product Number：K60120-1 / 76285
Shanghai Lincoln Electric Company
No195, Lane 5008, HuTai Road Shanghai 201907
Tel: [phone] Fax: [phone]
TM
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 thoughtful operation on your
part. DO NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and
be careful.
OPERATOR’S MANUAL
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

i SAFETY i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE
SERIOUS INJURIES OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD
CONSULT WITH THEIR DOCTORS 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
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
1.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables and welding machines.
1.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult with their physician
before welding.
1.c. Exposure to EMF fields in welding may have other health effects which are now not known.
1.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1.d.1. Route the electrode and work cables together. Secure them with tape when possible.
1.d.2. Never coil the electrode lead around your body.
1.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side,
the work cable should also be on your right side.
1.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
1.d.5. Do not work next to welding power source.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous
WARNING
!

ii SAFETY ii
2.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do not touch
these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
2.b. Insulate yourself from work and ground using dry insula-
tion. Make certain the insulation is large enough to cover
your full area of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
Semiautomatic DC Constant Voltage Wire
Welder.
DC Manual (Stick) Welder.
AC Welder with Reduced Voltage Control.
2.c. In semiautomatic or automatic wire welding, the electrode
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
2.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
2.e. Ground the work or metal to be welded to a good electri-
cal (earth) ground.
2.f. Maintain the electrode holder, work clamp, welding cable
and welding machine in good, safe operating condition.
Replace damaged insulation.
2.g. Never dip the electrode in water for cooling.
2.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because
voltage between the two can be the total of the open
circuit voltage of both welders.
2.i. When working above floor level, use a safety belt to
protect yourself from a fall should you get a shock.
2.j. Also see items 5.c. and 8.
3.a. Use a shield with the proper filter and cover plates to
protect your eyes from sparks and the rays of the arc
welding or observing open arc welding.
The headshield and filter lens should conform to ANSI
Z87.I standards.
3.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.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.
4.a. Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. When
welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and
gases away from the breathing zone.
When welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values
(TLV) using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors,
a respirator may be required. Additional precautions
are also required when welding on galvanized steel.
4.b. Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with
solvent vapors to form phosgene, a highly toxic gas, and
other irritating products.
4.c. Shielding gases used for arc welding can displace air
and cause injury or death. Always use enough ventila-
tion, especially in confined areas, to insure breathing air
is safe.
4.d. Read and understand the manufacturer’s instruction for
this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and
follow your employer’s safety practices. MSDS forms are
available from your welding distributor or from the
manufacturer.
ELECTRIC SHOCK
can kill.
ARC RAYS can burn.
FUMES AND GASES
can be dangerous.

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

iv SAFETY iv
Thank 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 the nameplate of your machine.
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:
This statement appears where the information must be followed exactly to avoid serious personal
injuries or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or
damage to this equipment.
WARNING
!
!
CAUTION

i CONTENTS i
Installation Section A
Technical Specification A-1
Safety Precautions A-1
Installation Instructions A-2
Welding Cable A-2
Gas Hose A-2
Control Cable A-2
Option Extension Cables A-2
Welding Gun A-2
Connection Diagram: LWFTM Wire Feeder to Lincoln Power Source A-2
Operation Section B
Installing Drive Rolls B-1
Loading the Wire Spool B-1
The Cold-inch and Gas-purge Button B-2
Symbol descriptions B-2
Maintenance Section C
Maintenance C-1
Schematic Diagram Section D
Schematic Diagram D-1

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS –LWFTM Wire Feeder
MODEL
LWFTM-4GS
INPUT POWER
Supplied by power source
RECOMMENDED WIRE SIZES
0.8mm, 1.0mm, 1.2mm, 1.4mm, 1.6mm,2.0mm
WIRE FEED SPEED
1.5 to 22 m/min
WELDING WIRE SPOOL (Max. load 20 kg)
SHAFT DIAMETER
OUTSIDE DIAMETER
WIDTH
50mm
300mm
98mm
DIMENSIONS & WEIGHT (Without Welding Wire Spool)
Specification
Model
HEIGHT
WIDTH
DEPTH
WEIGHT
LWFTM-4GS
400mm
230mm
620mm
14.1kg
Note: Please only use this wire feeder with specified power sources, otherwise no
output will be produced and the machine may be damaged.
SAFETY PRECAUTIONS
·Turn off the input power at the fuse box before working on other
equipment connected to the welding system at the disconnect
switch or fuse box before working on this equipment.
Do not touch electrically hot parts.
INSTALLATION INSTRUCTION
!
WARNING
ELECTRIC SHOCK can kill.
· Only qualified personnel should perform this installation, mainte-
nance and troubleshooting work.

A-2 INSTALLATION A-2
WELDING CABLE
The needed cable assembly for the LWFTM-4GS wire feeder includes control cable, welding cable and
gas hose. The lengths are made based on to the specific requirements from end users. The wire feeder
has a stud being used to connect the welding cable.
For self-shielded wire, the welding cable should be bolted to either the “+” or “-“output stud on power
source.
For Gas shielded wire, the power cable should be bolted to “+” output stud on power source.
GAS HOSE
The LWFTM-4GS interconnection cable assembly has a gas hose which connects to the rear panel on
the wire feeder. The other end of the hose connects to gas flow regulator. Shielding gas such as CO2,
Ar, and blend gas can be used and the gas pressure cannot be more than 0.7 MPa.
CONTROL CABLE
The control cable is included in the interconnection cable assembly. When it is used with DURAWELD &
OPTIMARC, the 6-pin connector on the control cable will be linked to the rear panel of the wire feeder
and 6-pin connector on the power source.
OPTION EXTENSION CABLES
The LWFTM-4GS wire feeder can also be used with extension welding cable/ control cable/ gas hose.
Note: Fix the hose and cables into the holding bracket on the rear of the feeder after your connection.
WELDING GUN
Insert the gun connector to the ‘Euro Connector’ on the front panel of the wire feeder and screw the
hand nut up tightly.
CONNECTION DIAGRAM: LWFTM Wire Feeder to Lincoln Power Source
INSTALLING DRIVE ROLLS

B-1 OPERATION B-1
Two reversible drive rolls need to be installed on each LWFTM-4GS wire feeder. Loosen the gland nut
and put on the drive roll, then tighten the gland nut (see FIGURE B.1). Normally each drive roll has two
different size grooves for feeding different diameter wire. Ensure that the drive roll is installed using the
correct groove for the wire diameter being used.
Note: Ensure the specifications of the 2 symmetrical drive rolls are same, otherwise wire feeder feeding
issues could arise.
FIGURE B.1-WIRE FEEDER MOTOR ASSEMBLY
LOADING THE WIRE SPOOL
FIGURE B.2-WIRE FEEDER
Open the wire box and the left panel, then loosen the retainer on the spindle and put on the welding
wire spool (see FIGURE B.2). Next, replace the retainer and tighten. Release the pressure handles and
lift the pressure arms, insert the welding wire into inlet guide and V groove of the drive roll, then insert it
into the intermediate guide. Now insert the welding wire into V groove of the other drive roll and outlet
guide. Re-engage the pressure handles. Adjust the pressure to feed wire smoothly by rotating the
pressure handles. Then using the cold-inch button on the feeder to begin feeding wire. Release the
cold-inch button when the wire comes out 1-2cm from the outlet guide. The installation of the welding
wire is now completed (see FIGURE B.1).
Note: When the wire feeder is first used, you should loosen the black screw at the bottom of the wire
box to open it.
TIGHT
TIGHT
TIGHT

B-2 OPERATION B-2
THE COLD-INCH AND GAS-PURGE BUTTON
FIGURE B.3-BUTTON
Open the left panel, you can see the cold-inch and gas-purge button as shown in FIGURE B.3.
SYMBOL DESCRIPTIONS
SYMBOL
DESCRIPTION
GAS PURGE BUTTON
COLD INCH BUTTON
GAS INLET
COOLING WATER INLET
COOLING WATER OUTLET

C-1 MAINTENANCE C-1
Note: Motor and gear box are maintenance free products, do not open them for maintaining, repairing or
oiling. Contact your nearest Lincoln Electric Service Center if a fault occurs.
Location
Inspection Points
Note
Wire Outlet
Check if there is any dust and
metal particles accumulated
at the entrance of the wire
outlet and on the surface of
the drive rolls.
Clean the dust and metal
particles and find out the
cause.
Check if the diameter of the
outlet suits the wire diameter.
If not suitable, erratic arc or
metal particles will occur.
Check if the end of the wire
outlet is lined up with the V
groove of the drive roll.
(Visual inspection)
If they are not lined up,
erratic arc or metal particles
will occur.
Drive rolls
Check if the size of the drive
roll is suitable for the diameter
of the wire used.
Check if there is any fragment
sticking in the groove.
Metal particles and dust in
liner will cause erratic arc.
Replace if abnormal.

D-1 SCHEMATIC DIAGRAM D-1
M
X
GUN
TRIGGER COLD-INCH
BUTTON
5
4
3
6
2
1
VOLTAGE
REGULATOR
FEED
MOTOR
CURRENT
REGULATOR
5kΩ
5kΩ
4.7kΩ
10kΩ
221Ω
GAS-PURGE
BUTTON
2.5kΩ
P1
P2
P3
P4
GAS
VALVE
Shanghai Lincoln Electric Company
No195, Lane 5008, HuTai Road Shanghai 201907
Tel: [phone] Fax: [phone]