Lincoln Electric PWF-2 User manual

IM7101-1
July, 2018
Rev. D
PWFTM-2/PWFTM-4 Wire Feeder
For Use With Wire Feeder Part Number: PWF-2 K60024-3
PWF-2 Plus K60006-3
PWF-4 K60024-9
PWF-4 Plus K60006-6
The Shanghai Lincoln Electric Co., Ltd
No195, Lane 5008, Hu Tai Road Shanghai 201907
Tel: [phone] Fax :( 021)5602 0345
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

i SAFETY i
WARNING
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. Please see www.lincolnelectric.com.cn for details.
BE SURE THATALL INSTALLATION, OPERATION, MAINTENANCEAND REPAIR PROCEDURES
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous
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.

ii SAFETY ii
2.a The welding gun and work (or ground) circuits are electrically “hot” when the welding operator
presses the trigger. 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 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
2.c In semiautomatic or automatic wire welding, the electrode, electrode wire, 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 electrical (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 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.
ELECTRIC SHOCK can kill.

iii SAFETY iii
___
ARC RAYS can burn.
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.
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.
FUMES AND GASES can be dangerous.
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 ventilation, 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.

iv SAFETY iv
WELDING SPARKS can cause fire or explosion.
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. See
www.lincolnelectric.com.cn for details.
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 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.
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.

v SAFETY v
CYLINDER may explode if damaged.
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. If available, valve protection caps should always be in place if available 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 and associated equipment.
FOR ELECTRICALLY Powered Equipment.
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 local codes and the manufacturer’s
recommendations.
7.c. Ground the equipment in accordance with the local codes and the manufacturer’s
recommendations.

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 ______________________
Purchased From ______________________
Whenever you request replacement parts for or information on this equipment
always supply the information you have recorded above.
Read this Operator’s 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
■ Installation Section A
Technical Specification A-1
Safety Precautions A-2
Interconnection Cable A-2
Welding cable A-2
Gas Hose A-2
Control Cable A-2
Welding Gun A-3
Connection Diagram: PWFTM Feeder to Lincoln POWERPLUS™ A-3
■ Operation Section B
Installing Feed Rolls B-1
Loading the Wire Spool B-1
■ Maintenance Section C
Maintenance C-1
■ Schematic Diagram Section D
Schematic Diagram D-1
■Parts List Section E
PWFTM-2/4 Remote Control E-2
PWFTM-2/4 General Parts E-3
PWFTM-2 Replacement Parts Diagram E-4
PWFTM-2 Replacement Parts List E-5
PWFTM-4 Replacement Parts Diagram E-6
PWFTM-4 Replacement Parts List E-7
PWFTM-2 Plus/ 4 Plus Special Spare Parts List (Diagram) E-8
Consumable Parts List Section F
PWFTM-2/4 Consumable Parts F-1

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS –PWF™ Wire Feeder
MODEL
PWFTM-2, PWFTM-4, PWFTM-2 Plus, PWFTM-4 Plus
VOLTAGE OF FEEDER MOTOR
Supplied by power source, DC 18.3 V
RECOMMENDED WIRE SIZES
0.8mm,1.0mm,1.2mm,1.4mm,1.6mm,2.0 mm
WIRE FEED SPEED
1.5-22m/min
WIRE SPOOL（Max. load 20 KG）
Shaft diameter
50mm
Outer diameter
280mm
Width
105mm
DIMENSIONS & WEIGHT (Without wire spool)
Specification
Model
HEIGHT
WIDTH
DEPTH
WEIGHT
PWFTM-2
350mm
280mm
450mm
10.5kg
PWFTM-4
11.0kg
PWFTM-2 Plus
350mm
280mm
550mm
12.0kg
PWFTM-4 Plus
12.5kg
Note: Please use this wire feeder with specified POWERPLUS™, INVERTEC® (Peak value of 50V for
DC pulse) power sources. Failure to do so could result in no output or damage to machine.

A-2 INSTALLATION A-2
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
Only qualified personnel should perform this installation,
maintenance and troubleshooting work.
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.
■INTERCONNECTION CABLE
The interconnection cable assembly for the PWF™ feeders includes a control cable, welding cable and
gas hose. Preset lengths are available from Lincoln Electric.
■WELDING CABLE
Connect the welding cable to the stud at the rear of the wire feeder. For gas shielded wire, the welding
cable should be bolted to “+” output stud on the power source.
■GAS HOSE
The PWF™interconnection cable assembly has a gas hose which connects to the gas nipple on the rear of the
feeder. The other end of the gas hose, connects to the flow meter/regulator. Please secure both ends of gas
hose suitable hose clips. Shielding gas such as CO2, Ar, and blended gas can be used. (Gas pressure can not
be more than 0.7 MPa)
■CONTROL CABLE
The control cable is included in the interconnection cable assembly. When it is used with POWERPLUS™,
the 6-pin connector on the control cable will be connected to the rear panel of the wire feeder and 6-pin
connector on the power source.
**Notes: Please fix the gas hose and cables into the holding bracket on the rear of the
feeder after the connection.
WARNING

A-3 INSTALLATION A-3
■WELDING GUN
Lay the welding gun out straight. Insert the connector on the welding gun into the brass
conductor block on the front of the wire feeder. Make sure it is all the way in and tighten the
hand wheel clamp. Keep this connection clean at all times.
■Connection Diagram: PWFTM Feeder to Lincoln POWERPLUS™
Note:
Make sure welding cables are securely fastened.
Gas cylinder must be secure at all times.

B-1 OPERATION B-1
INSTALLING FEED ROLLS
PWF™-2: One reversible drive roll needs to be installed on each PWFTM-2 wire feeder. Normally each drive roll has
two different size grooves for feeding different diameter wire. One groove is for feeding 0.8/1.0/1.2mm and the other
groove is for feeding 1.0/1.2/1.6mm. Ensure that the drive roll is installed using the correct groove for the wire diameter
being used.
PWF™-4: Two reversible drive rolls need to be installed on each PWFTM-2 wire feeder. Normally each drive roll has
two different size grooves for feeding different diameter wire. One groove is for feeding 1.0/1.2mm and the other groove
is for feeding 1.2/1.6mm. Ensure that the drive roll is installed using the correct groove for the wire diameter being used.
Notice: make sure the specifications of the 2 symmetrical feed rolls are same. And don’t make any mistake about it!
LOADING THE WIRE SPOOL
PWF™-2
Loosen the retainer on the spindle and put on the welding wire spool. Next, replace the retainer and tighten the screw.
Release the pressure handle and lift the pressure arm, then insert the welding wire into the inlet straightening rolls 2-3cm (1
inch). Now, replace the pressure arm and tighten with the pressure handle noting that the pressure scale should suit the
wire diameter. Using the cold-inch button on the feeder, begin feeding wire. Release the cold-inch button when the wire
comes out 1-2cm (1/2-1 inch) from the contact tip. The installation of the welding wire is now completed.

B-2 OPERATION B-2
PWF™-4
Loosen the retainer on the spindle and put on the welding wire spool. Next, replace the retainer and tighten the screw.
Release the pressure handle and lift the pressure arm, insert the welding wire into conduit and V groove of feed roll, then
insert it into the feedplate. Then insert the welding wire into V groove of another feed roll and contact tip. Push down the
pressure handle at last. Adjust the pressure to feed wire smoothly. Then using the cold-inch button on the feeder, begin
feeding wire. Release the cold-inch button when the wire comes out 1-2cm (1/2-1 inch) from the contact tip. The
installation of the welding wire is now completed.
Pressure Handle
Pressure Arm
Intermediate Guide
Drive Roll
Wire
Inlet Guide Tube
Pressure Roll
Outlet Guide Tube
Gun Receiver

C-1 MAINTENANCE C-1
Location
Inspection Points
Note
Wire Outlet
Check if there is any dust
and powder accumulated
at the entrance of the
wire outlet and on the
surface of the feed rolls.
Clean the dust and powder
and find out the cause.
Check if the diameter of
the outlet suits the wire
diameter.
If not suitable, erratic arc or
powder will occur.
Check if the end of the
wire outlet is lined up
with the V groove of the
feed roll. (Visual
inspection)
If they are not lined up,
erratic arc or powder will
occur.
Feed Rolls
Check if the diameter of
the feed roll is suitable
for the diameter of the
wire used.
Check if there is any
fragment sticking in the
groove.
Powder and jam in liner
will cause erratic arc.
Replace if abnormal.
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.

D-1 SCHEMATIC DIAGRAM D-1
GS

E-1 PARTS LIST E-1
PARTS LIST
This parts list is provided as an informative guide only.
This information was accurate at the time of printing. Always
check with your parts supplier for the latest parts information.
PWF™ - 2 / 4 / 2Plus / 4Plus
Wire Feeder

E-2 PARTS LIST E-2
REMOTE CONTROLASSEMBLY
Item
Symbol
Description
Part Number
Quantity
1
Remote Control Box
Assembly
KP61072-5
1
2
Gas Purge Button
1
3
Cold Inch Button
1
4
Potentiometer Knobs
(WFS/Voltage adjustment)
KP61063
2
2
3
3
4
1

E-3 PARTS LIST E-3
PWF™-2/ PWF™-4 GENERALPARTS ASSEMBLY
2-11
2-3
2-2
2-4 2-5
2-6
2-8
2-9 2-1
2-7
2-15
2-10
2-10
2-1
2-14
2-16
2-13
Item
Description
Specificatio
n
Part Number
Qty.
2-1
Wire Feeder Frame
Frame
KP61073-1
KP61073-2(plus)
1
2-2
Gas Valve
KP61074
1
2-3
Gun Switch Receptacle
MT25B2P
KP61076
1
2-4
Spool Shaft
Damping
KP61078
1
2-6
Spool Stopper
KP61091
1
2-8
Insulation Foot
KP61090
2
2-9
Front Cover
----
1
2-10
Motor/Drive Assembly
Single
driven
KP61088
1
Dual driven
KP61254
1
2-11
Motor Insulating Plate
KP61092
1
2-13
Cable Bracket
----
1
2-14
Transitional cable and stud
----
1
2-15
Transitional lead and socket
KP61156
1
2-16
Transitional gas hose and nozzle
KP61096
1

E-4 PARTS LIST E-4
PWF™-2 REPLACEMENT PARTS DIAGRAM

E-5 PARTS LIST E-5
PWFTM-2 REPLACEMENT PARTS
No.
Description
Specification
Part Number
Qty.
10
Feed Motor
120SN05-C
KP61088
1
11
Pressure Arm
KP61098-1
KP61214
1
12
Axle screw (5)
KP61215
1
13
Axle screw (2)
KP61216
1
14
Pressure Roll
KP61217
1
15
Axle screw (5)
KP61107-1
KP61215
1
16
Pressure Arm Bolt
KP61219
1
17
Plain Washer
KP61220
1
18
Scale Cover
KP61221
1
19
Pressure Spring
KP61222
1
20
Handle
KP61223
1
21
Gun receiver
Asia
KP61108-1
1
22
Hex Bolt
1
23
Hex Head Cap Bolt
1
24
Conduit
See consumable
parts
1
25
Insulator
KP61111
2
26
Bracket
KP61113-1
KP61224
1
27
Petal Nut
KP61225
1
28
Adjustment Bolt
KP61226
1
29
Straightening Roll
KP61227
3
30
Pressure Spindle
KP61228
2
31
Adjustment Bracket
KP61229
1
32
E Type Holding Ring
KP61230
1
33
Axle screw (4)
KP61231
1
34
Axle screw (5)
KP61215
1
35
Screw
----
1
36
Nut
----
1
** Standard parts of wire feeder.