Lincoln Electric DLF-72 User manual

Operator’s Manual
®
DLF-72
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IM10632 | Issue Date Feb – 22
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
13237, 13238, 13239
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
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Hours of Operation:
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THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
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.
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.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and 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 helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 10/08/2021

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when usedfor welding or
cutting, produces fumes or gases which contain
chemicals known to the State ofCalifornia to cause
birth defects and, in some cases, cancer.(California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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. 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 POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
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. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
causes localized Electric and Magnetic Fields (EMF).
and welding machines
welders having a pacemaker should consult their physician
before welding.
which are now not known.
2.d. All welders should use the following procedures in order to
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.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.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 10/08/2021
1.c. Do not add the fuel near an open ame welding
with hot engine parts and igniting. Do not spill fuel when lling
2.a. Electric current owing through any conductor
Welding current creates EMF elds around welding cables
2.b. EMF elds may interfere with some pacemakers, and
2.c. Exposure to EMF elds in welding may have other health effects
minimize exposure to EMF elds from the welding circuit:
1.i. Using a generator indoors CAN KILL YOU IN
MINUTES.
1.j. Generator exhaust contains carbon monoxide. This is a poison
you cannot see or smell.
1.k. NEVER use inside a home or garage,
EVEN IF doors and windows are open.
1.l. Only use OUTSIDE and far away from
windows, doors and vents.
1.m. Avoid other generator hazards. READ
MANUAL BEFORE USE.

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.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.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. 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 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
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 10/08/2021

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.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.
6.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.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.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.
6.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.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. 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.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 10/08/2021

2
DLF-72®TABLE OF CONTENTS
GENERAL DESCRIPTION ........................................................................................................................................3
PROCESS LIMITATIONS.........................................................................................................................................3
EQUIPMENT LIMITATIONS .....................................................................................................................................3
RECOMMENDED POWER SOURCES.......................................................................................................................3
OTHER POWER SOURCES......................................................................................................................................3
DESIGN FEATURES................................................................................................................................................3
INSTALLATION .............................................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS ............................................................................................................................A-2
LOCATION .........................................................................................................................................................A-
RECOMMENDED ELECTRODE AND WORK CABLE SIZES FOR ARC WELDING ......................................................A-3
TRIGGER CONNECTOR.......................................................................................................................................A-3
CHANGING THE GUN ADAPTER BUSHING ...........................................................................................................A-5
PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES................................................................................A-4
PRESSURE ARM ADJUSTMENT..........................................................................................................................A-4
GUN CONNECTION.............................................................................................................................................A-6
SHIELDING GAS CONNECTION ...........................................................................................................................A-6
OPERATION ................................................................................................................................................SECTION B
POWER-UP SEQUENCE ......................................................................................................................................B-1
.......................................................................................B-2
........................ ...................................................B-4
OPTIONS/ACCESSORIES...............................................................................................................................SECTION C
MAINTENANCE .............................................................................................................................................SECTION D
ROUTINE MAINTENANCE ...................................................................................................................................D-1
PERIODIC MAINTENANCE ..................................................................................................................................D-1
TROUBLESHOOTING .....................................................................................................................................SECTION E
DIAGRAMS .................................................................................................................................................SECTION F
PARTS LIST ...............................................................................................................PARTS.LINCOLNELECTRIC.COM
CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION
MANUALS, GO TO PARTS.LINCOLNELECTRIC.COM.
POWER-UP SEQUENCE ......................................................................................................................................B-1
CASE FRONT CONTROLS....................................................................................................................................B-6
INTERNAL CONTROLS ........................................................................................................................................B-7
REAR CONNECTIONS..........................................................................................................................................B-8
D...................................................................................................................B-3
.................................................... ..............................................................................B-5
.. .....................................................................................B-2
RECOMMENDED PROCESSES................................................................................................................................3

RECOMMENDED PROCESSES
PROCESS LIMITATIONS
• Does not support CC mode operation.
EQUIPMENT LIMITATIONS
RECOMMMENDED POWER SOURCES
OTHER POWER SOURCES
DESIGN FEATURES
Loaded with Standard Features Controls
3
• Rating - 600 amp, 60% duty cycle rating.
• 0.023 - 1/16” (0.6 - 1.59mm) GMAW Wire Diameters.
• Gas apparatus - can be used for FCAW and GMAW processes.
GENERAL DESCRIPTION
The DLF-72 is a light-weight, portable, ArcLink® enabled feeder.
The DLF-72 has been designed for benchtop use in heavy
applications. It can also accomodate up to a 60 lb. spool or
direct feed from a bulk wire package.
The DLF-72 comes factory equipped with a K3345-1 Magnum®
Tweco-compatible style #2-#4 gun adapter. Other gun adapters
In addition to ArcLink®, the DLF-72 wire feeder has the
following features:
• Large Digital Displays with dedicated voltage and wire feed
speed knobs.
•Trigger interlock for comfort when making long
welds.
• Cold-feed button for wire feeding without activating welding
output.
• Gas Purge button for purging the gas path without activating
welding output.
• The following options are available from the setup menu:
- Variable run-in speed for smoother arc starting.
- Burnback time provides adjustable power source output
shutoff to prevent the electrode from sticking in the
crater.
coverage before and after each weld.
DLF-72
®
industrial fabrication and job shops. This reliable, industrial
style guns.
• 0.035 - 5/64” (0.9 - 1.59mm) FCAW Wire Diameters.
• The OLED Display allows for simple process navigation and
pulse weld mode selection.
• The heart of the DLF-72 is the 2 roll MAXTRAC® drive. The
patented features on the wire drive offer tool-less changing of
the drive rolls and wire guides for quick spool changes. A
tachometer controlled motor powers the patented drive rolls for
smooth, steady feeding without slippage.
• GMAW
• FCAW
• Flextecs
• Presettable voltage and wire feed speed.
• Supports external Dual Procedure Selection Switch.
• ArcLink® Enabled Vantages

A-1
INSTALLATION
READ ENTIRE INSTALLATION SECTION BEFORE
INSTALLING THE DLF-72.
INSTALLATION
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box before
attempting to connect or disconnect
input power lines, output cables or
control cables.
installation.
SELECT SUITABLE LOCATION
For best wire feeding performance, place the DLF-72 on a stable
and dry surface. Keep the wire feeder in a vertical position. Do
not operate the wire feeder on an angled surface of more than
15 degrees.
Do not submerge the DLF-72.
The DLF-72 is rated IP2x and is suitable for indoor use.
When suspending a wire feeder, use the intended lift bale to
ensure insulation from the hanging device.
High Frequency Interference Protection
Locate the DLF-72 away from radio controlled machinery.
The normal operation of the DLF-72 may adversely affect
the operation of the RF controlled equipment, which may
result in bodily injury or damage to the equipment.
CAUTION
WARNING
DLF-72®
LOADING SPOOLS AND COILS
• Keep hands, hair, clothing and tools away from rotating
equipment.
• Do not wear gloves when threading wire or changing
wire spool.
this equipment.
WARNING
Do not place bench models on inclined plane of more than 15
degrees from horizontal for risk of toppling over.
60974-10.

A-2
INSTALLATION
TECHNICAL SPECIFICATIONS -
INPUT - SINGLE PHASE
Input Voltage +/- 10%
Input Amperes @ Rated
Output
40V DC
6A
MODEL SUMMARY
K# Description Meters Drive Roll Kit
Included
Feed Plate Gun Adapter
Installed
K5280-1 DLF-72 DIGITAL .035/.045
Spur K3345-1
RATED OUTPUT (ALL MODELS)
Duty Cycle Amperes
60% 600A
PHYSICAL DIMENSIONS
Model Height Width Depth Weight
K5280-1 12 in.
(305 mm)
11.25 in.
(286 mm)
11.5 in.
(292 mm)
33 lbs.
TEMPERATURE RANGES
OPERATING TEMPERATURE
RANGE
STORAGE TEMPERATURE
RANGE
-14°F to 104°F (-10°C to 40°C) -40°F to 122°F (-40°C to 50°C)
Thermal tests have been performed at ambient temperature.
PROCESS WIRE DIAMETER RANGE WIRE FEED SPEED RANGE
GMAW 0.023 - 1/16” (0.6 - 1.59mm)
40 - 800 IPM (1 - 20.3 m/minute)
FCAW 0.035 - 5/64” (0.9 - 1.59mm)
DLF-72®
K5280-2 DLF-72 Bench Model DIGITAL .035/.045
Spur K3345-1
K5280-3 DLF-72 Bench Model with Gun DIGITAL .035/.045
Spur K3345-1
K5280-2 15.65 in.
(398 mm)
12 in.
(305 mm)
24.57 in.
(624 mm)
32.5 lbs.

A-3
INSTALLATION
RECOMMENDED ELECTRODE AND WORK CABLE
SIZES FOR ARC WELDING
(See Table A.1)
Tabulated below are copper cable sizes recommended for
different currents and duty cycles. Lengths stipulated are the
distance from the welder through work and back to the welder
again. Cable sizes are increased for greater lengths primarily for
the purpose of minimizing cable drop.
TRIGGER CONNECTOR
There is one circular connector for the gun trigger on the front of
the DLF-72.
ELECTRIC SHOCK CAN KILL.
• Do not touch electrically live parts.
WARNING
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F OR 75°C)**
Amperes PERCENT
DUTY CYCLE
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
200 60 22211/0
200 100 22211/0
225 20 4 or 5 34 or 5 11/0
225 40 & 30 33311/0
250 30 33311/0
250 40 22211/0
250 60 11111/0
250 100 11111/0
300 60 1111/0 1/0
350 100 2/0 2/0 2/0 2/0 2/0
350 60 1/0 1/0 1/0 2/0 3/0
400 60 2/0 2/0 2/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
500 60 2/0 2/0 2/0 3/0 4/0
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).
TABLE A.1
Picture Function Pin Wiring
5 PIN TRIGGER
CONNECTOR
A GUN TRIGGER SWITCH SUPPLY
B NOT USED
C GUN TRIGGER SWITCH
D DUAL PROCEDURE SWITCH
E DUAL PROCEDURE SWITCH SUPPLY
A
E
CB
D
DLF-72®

A-4
INSTALLATION
PROCEDURE TO INSTALL DRIVE ROLLS AND
WIRE GUIDES
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding power source
before installation or changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger,
electrode and drive mechanism are
"hot" to work and ground and could
remain energized several seconds
after the gun trigger is released.
• Do not operate with covers, panels or guards removed
or open.
work.
1. Turn power off at the welding power source.
2. Release the idle roll pressure arm.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them from the
feedplate.
4. Rotate the locking hub lock and remove the drive rolls.
5. Remove the inner wire guide.
6. Insert the new inner wire guide, groove side out, over the
two locating pins in the feedplate.
7. Install a drive roll on each hub assembly secure with the
locking hub.
8. Install the outer wire guide by aligning it with the pins and
tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressure arm.
Adjust the pressure appropriately.
PRESSURE ARM ADJUSTMENT
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding
power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and drive
mechanism are "hot" to work and ground and could
remain energized several seconds after the gun trigger
is released.
• Do not operate with covers, panels or guards removed
or open.
work.
The pressure arm controls the amount of force the drive rolls exert
on the wire. Proper adjustment of the pressure arm gives the best
welding performance.
Set the pressure arm as follows:
WARNING WARNING
FIGURE A.3
1
2
Aluminum
FCAW
GMAW
45
6
3
Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
UNLOCKED
POSITION
LOCKED
POSITION
DLF-72®

A-5
INSTALLATION
CHANGING THE GUN ADAPTER BUSHING
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding
power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and drive
mechanism are "hot" to work and ground and could
remain energized several seconds after the gun trigger
is released.
• Do not operate with covers, panels or guards removed
or open.
work.
Tools required:
• 1/8" hex key wrench
Note: Some gun adapters do not require the use
of the thumb screw.
1. Turn power off at the welding power
source.
2. Remove the welding wire from the wire drive.
3. Remove the thumb screw from the wire drive.
4. Remove the welding gun from the wire drive.
7. Loosen the Hex Head Set Screw that holds
the gun adapter in place. Important: Do not
attempt to completely remove the Hex
Head Set Screw.
8. Remove the outer wire guide, and push the
gun adapter out of the wire drive. Because of
required to remove the gun bushing.
9. Disconnect the shielding gas hose from the
gun bushing, if required.
10. Connect the shielding gas hose to the new
gun adapter, if required.
11. Rotate the gun adapter until the thumb screw
hole aligns with the thumb screw hole in the
feedplate. Slide the gun receiver bushing
into the wire drive and verify the thumb
screw holes are aligned.
12. Tighten the Hex Head Set Screw.
14. Insert the welding gun into the gun adapter
and tighten the thumb screw.
WARNING
Gun Adapter
Thumb Screw
FIGURE A.2
DLF-72®
• Phillips Head Screwdriver
6. Remove Sense Lead connection from gun
adapter by loosening phillips head screw.
15. Replace sense lead connection by placing
phillips head screw into gun bushing adapter
and tighten.
Outer Wire Guide
• 3/4” Wrench
5. Remove 3/4" bolt from gun adapter to remove
weld cable.
13. Place 3/4" screw onto weld cable and tighten
on-to gun adapter.
Sense Lead Connection
Socket Head Cap Screw

A-6
INSTALLATION
GUN CONNECTION
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding power source
before installation or changing drive
rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger,
electrode and drive mechanism are
"hot" to work and ground and could remain energized
several seconds after the gun trigger is released.
• Do not operate with covers, panels or guards removed
or open.
work.
The DLF-72 comes with an adapter installed, that accepts #2 -
#4 guns. To install a gun:
2. Remove the thumb screw.
3. Push the gun the completely into the gun bushing.
4. Secure the gun in place with the thumb screw.
5. Connect the trigger cable from the gun to the trigger
connector on the front of the feeder.
Note: Not all gun bushings require the use of the thumb screw.
SHIELDING GAS CONNECTION
CYLINDER may explode if
damaged.
• Keep cylinder upright and chained
to support.
• Keep cylinder away from areas
where it may be damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live electrical
circuits.
Build up of shielding gas may
harm health or kill.
• Shut off shielding gas supply when
not in use.
• See American National Standard
Z-49.1, "Safety in Welding and
Cutting” Published by the American Welding Society.
Maximum inlet pressure is 100 psi. (6.9 bar.)
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
2. Remove the cylinder cap. Inspect the cylinder valves and
regulator for damaged threads, dirt, dust, oil or grease. Remove
dust and dirt with a clean cloth. DO NOT ATTACH THE
REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT!
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.
union nut(s) securely with a wrench. Note: if connecting to
100% CO2cylinder, insert regulator adapter between regulator
and cylinder valve. If adapter is equipped with a plastic washer,
be sure it is seated for connection to the CO2cylinder.
regulator. Attach the other end to the welding system shielding
gas inlet. Tighten the union nuts with a wrench.
6. Before opening the cylinder valve, turn the regulator adjusting
knob counterclockwise until the adjusting spring pressure is
released.
7. Standing to one side, open the cylinder valve slowly a fraction
of a turn. When the cylinder pressure gage stops moving, open
the valve fully.
WARNING WARNING
Thumb
screw
1. Turn power OFF at the welding power source.
DLF-72®

B-1
OPERATION
OPERATION
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
ARC RAYS can burn.
• Wear eye, ear and body protection.
Observe additional Safety Guidelines detailed
in the beginning of this manual.
The serviceability of a product or structure utilizing the DLF-72
wirefeeder is and must be the sole responsibility of the builder/
user. Many variables beyond the control of The Lincoln Electric
Company affect the results obtained in using the DLF-72 wire-
feeder. These variables include, but are not limited to, welding
procedure, plate chemistry and temperature, weldment design,
fabrication methods and service requirements. The available
range of the DLF-72 wirefeeder may not be suitable for all
applications, and the builder/user is and must be solely
responsible for welding settings.
POWER-UP SEQUENCE
If the gun trigger is activated during power up, the feeder will not
operate until the gun trigger is released.
GRAPHIC SYMBOLS THAT APPEAR ON THIS
MACHINE OR IN THIS MANUAL
WARNING
DLF-72®
INPUT VOLTAGE
WARNING OR CAUTION
HIGH TEMPERATURE
READ INSTRUCTION
MANUAL
GAS INPUT
GAS OUTPUT
OUTPUT ON
GAS PURGE
A

B-2
INSTALLATION
TYPICAL SET-UP WITH ARCLINK®
(RECOMMENDED)
Place the power source in ArcLink® Mode.
Item K# Description
1
K5280-1
DLF-72
K3607-2 Flextec 500X Multi-Process Welder
2
KP1696-1 Drive Roll Kit
3
K4532-2-10-45
Magnum Pro Curve HDE 350
4
K2484-2
Work Cable
DLF-72®
WORK

B-3
OPERATION
DEFINITION OF WELDING TERMS
NON-SYNERGIC WELDING MODES
• A Non-synergic welding mode requires all welding process vari-
ables to be set by the operator.
SYNERGIC WELDING MODES
• A Synergic welding mode offers the simplicity of single knob
control. The machine will select the correct voltage and amper-
age based on the wire feed speed (WFS) set by the operator.
WFS
• Wire Feed Speed
CC
• Constant Current
CV
• Constant Voltage
GMAW
• Gas Metal Arc Welding
GMAW-STT
• Gas Metal Arc Welding-(Surface Tension Transfer)
SMAW
• Shielded Metal Arc Welding
FCAW
• Flux Core Arc Welding
CAG
• Carbon Arc Gouging
GTAW
•Gas Tungsten Arc Welding
DLF-72®

Figure B.1
DIGITAL METER OPERATION - WHILE WELDING
DIGITAL METER OPERATION - AFTER WELDING
DLF-72®
DIGITAL METER OPERATION - WHILE IDLE
The left display shows the preset wire feed speed while the right
display shows the preset voltage when it is connected to a power
source that supports the DLF-72 (see Figure B.1). The DLF-72 will
display "Err 262" if connected to an incompatible power source. If
the power source’s mode selection is not in ArcLink® Mode,
display will show “Sleep”.
The left display shows amps or WFS based on the selection in
the settings menu (the corresponding LED will be illuminated).
The right display shows Voltage.
The display continues to hold the value of the amperage
completion of each weld. The corresponding LEDs for
to identify these as “Look Back” values. Turning either
of the 2 knobs will cause the displays to show preset
information.
WIRE FEED SPEED/AMPS VOLTAGE PRESET
B-4

B-5
•
•
•
•
Arc Control
Burn Back
DLF-72®
Display Units (diSP):
The units shown on the left display while welding can be
changed from the default of Arc Current in Amps. When “diSP” is
selected in the menu, the right knob can be turned to select
“Curr” or “Feed”. Curr will show Arc Current in Amps. Feed will
display wire feed speed in inches per minute or meters per
minute depending on the setting of the Units Menu Item.
SETTINGS MENU:
There are 2 levels of menus that can be accessed on the DLF-72.
To enter the welding menu system, press the menu button on
the bottom right.
Rotating the left encoder knob will change the menu item.
Rotating the right encoder knob will change the menu item’s
setting.
Pressing the Menu Button again will exit the menu.
Settings Menu items are:
Arc Control (Arc):
In CV modes arc control is used to vary the pinch or inductance
When ACtL is selected in the setting menu, it will appear on the
left display. To change the value turn the right knob clockwise
to increase and counter-clockwise to decrease the value.
It can be adjusted from the range -10.0 to +10.0.
Units (Unit):
The wire feed speed settings can be viewed in Metric or Imperial
Units by selecting either "US" or "Euro" in the Units section of
the Setup Menu. By default "US" is selected.
Calibration Speed (CAL Spd):
This is used to calibrate the wfs meter to a known calibrated WFS
Meter. To calibrate the wire feed speed, before entering the Setup
Menu, use the following procedure:
- Navigate to the “CAL Spd” Menu Item
- Use the right encoder to increase or decrease the value
to 1.01
- Set the display to desired WFS Setpoint using the left
knob (ex: 400 IPM)
- Measure the actual WFS (ex: 405 IPM)
- Calibration Factor = Actual WFS / Set WFS
- For this example, 405/400 = 1.01
ADVANCED MENU:
The Advanced Menu can be accessed by pressing and holding the
Menu Button for 5 seconds. This menu allows the user to view
the Software Revision and restore the unit to factory default
settings. The menu items can be scrolled through by pressing the
Menu Button once in the Advanced Menu.
Restore Factory Default (dFLt):
The second menu item allows the user to restore the machine to
its factory defaults. The option can be selected by turning the
right knob when “dFLt” is selected.
•
•
Units Metric / Imperial
Display Arc Current/WFS
This setting changes the amount of time that the solenoid is held
closed before the welding torch is energized and the wire is fed.
trigger is pulled.
range can be adjusted to be off or adjusted between 0.1s and
10.0s.
This setting changes the amount of time that the gas solenoid is
held closed after the welding arc is commanded off. The welding
turned off here as well. It can also be adjusted between 0.1s and
10.0s.
Burnback Time (burn bAC):
the trigger is released and the wire is no longer being fed. It can
be used to reduce the wire stickout after a weld.
The default burnback time is Auto. It can be turned off in the
menu or adjusted between 0.05s - 0.250s.
Software Revision:
Checksum. This information may be useful when communicating
machine version to service.
Run-in Speed (% of weld WFS) (run):
Run-in speed is used to modify the wire feed speed during the
wire will begin to be fed at the run in speed. By default it is set

B-6
OPERATION
CASE FRONT CONTROLS
Wire Feed Speed Digital Display - The DLF-72 has a digital
display that shows the wire feed speed. This display is also
capable of displaying amperage and the setup menu.
Wire Feed Speed Knob - Use the Wire Feed Speed Knob to set
the rate of wire feed speed. The wire feed speed will be
displayed on the Wire Feed Speed Digital Display. During CV
operation, the wire feed speed will remain a constant value,
independent of arc voltage changes.
3. Voltage/Trim Digital Display - The DLF-72 has a digital
4. Voltage Knob - Use the Voltage Knob to set the voltage
and it will be displayed on the Voltage Digital Display. During
CV operation, the voltage will remain stable while welding.
Wire Feed Speed LED - The Wire Feed Speed and Amperage
LEDs will communicate what is being displayed on the Wire
Feed Speed Digital Display. When the Wire Feed Speed LED is
illuminated, wire feed speed is being displayed.
Amperage LED - When the Amperage LED is illuminated,
amperage is being displayed.
Voltage LED - The Voltage LED will be illuminated when the
Voltage Digital Display is displaying actual voltage.
DLF-72®
display that shows the voltage/trim between electrode and
work.
5.
6.
7.
8.
9.
10.
Five Pin Gun Trigger Connector -
The 5 Pin Gun Trigger
Connector is where the trigger that is attached to the welding
gun is connected. This will actuate the welding current when
the trigger is pulled.
Cold Inch Button - Push to activate wire drive motor without
energizing the feedplate and release to halt feeding.
Gas Purge /4-Step (4Stp) Operation
Gas Purge operation: press the button, As long as the button is
-
4
8
1
10
2
3
5
6
7
9
show "4stp" "off" or "on". The right knob can then be turned
clockwise or counter clockwise to turn 4 step mode on or off. The
case front LED next to the 4 step symbol will be on when 4 step is
on and off when it is off.
4 Step operation: press and release the button. The display will
11. Menu Button
in the menu it can be pushed again to exit the menu. Push and
hold for 5 seconds to enter the Advanced Menu. Pushing again
will exit the menu.
- Push this button to enter the setup menu. Once
4-Step (4Stp):
single trigger pull to sustain a weld output that will end once a
second trigger pull and release occurs. This setting allows for
more comfortable operation during prolonged welds.
When 4-Step displayed, the left display will show “4StP”. By
default it is “OFF”; to turn it on rotate the right knob clockwise.
The LED next to the 4 step symbol, 2 arrows up and 2 arrows
down, will illuminate. To turn it off, rotate the right knob
counter-clockwise and the LED will turn off.
11

B-7
OPERATION
INTERNAL CONNECTIONS
1. Pressure Arm Adjustment Knob
2. Spool Retainer
3. Spindle Brake
4. Gun Bushing
5. Thumb Screw
6. Socket Head Cap Screw For Gun Bushing
7. Drive Hubs
8. Inlet Wire Guide
DLF-72®
1
2
3
4
5
67
8