Lincoln Electric IM638 User Manual

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Clutched Aluminum Drive Roll Kits

KP1682 Series

February, 2006

INSTALLATION INSTRUCTIONS

Table of Contents

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Description . . . . . . . . . . . . . . . . . . . . . .1

Kit Sizes and Contents . . . . . . . . . . . . . . . . . . . .2

Installation Instructions (2-Roll Feeders) . . . . . . .3

Installation Instructions (4-Roll Feeders) . . . . . . .4

Recommended Guns, Liners and Tips . . . . . . . .5

SAFETY

Follow all safety guidelines in your power source and feeder operators manuals and any additional guidelines
covered in this manual.

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

GENERAL DESCRIPTION

The KP1682 series of drive roll kits are optimized to feed aluminum MIG wires with the following wire feeders:

2-Roll Feeders 4-Roll Feeders
LN-25 Synergic 7
LN-7 LN-7
LN-742 LN-742

The drive rolls are specifically designed to minimize any wire deformation while the mechanical clutch is specifi­cally designed to prevent wire birdnesting by limiting the amount of feeding force on the wire.

The guide tubes are constructed of a high density plastic that supports the wire directly from the drive rolls yet
does not scrape the wire.

Design features of the clutched drive roll system:

• The drive roll pressure is preset to obtain the correct feeding force without deforming the wire. Readjusting
the idle roll tension may place too much force on the wire, thus deforming it. However, too little tension may
allow the wire to slip at the drive rolls. We have preset the tension at the factory. No further adjustment
should be necessary. (2-roll feeders ONLY)

• The clutch is designed to disengage before the wire can birdnest. The slip force is set according to the wire
size. The spring tension is preset at the factory. No further adjustment should be necessary.

• The drive roll and idle roll are manufactured with a groove design that supports the wire without crushing it.
We recommend that for every spool of wire, the rolls be removed and the grooves cleaned of any residual alu­minum build up. An abrasive string works well. As residual aluminum builds up, the drive rolls will deform the
wire and feeding performance will degrade.

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

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KIT SIZES & CONTENTS

The table and figures below list and illustrates the various K1682 series clutched aluminum drive roll kits for the
various wire sizes. Included with each KP1682 series kit are the components needed for 2-roll and 4-roll feeders.
Each kit includes the following items:

Drive Roll Kit KP1682-035A KP1682-1.0A KP1682-3/64A KP1682-1/16A

Metric Wire Size 0.9 mm 1.0 mm 1.2 mm 1.6 mm
English Wire Size .035 in .040 in 3/64 in (.047) 1/16 in (.063)

Included Items
1 Clutch Bolt S24474 S24474 S24474 S24474
2 Spring T11862-59 T11862-59 T11862-59 T11862-59
3 Clutch Pad (Qty. 2) S24475 S24475 S24475 S24475
4 Drive Roll S24480-035A S24480-1.0A S24480-3/64A S24480-1/16A
5 Outgoing Guide Tube S24479-035A S24479-3/64A S24479-3/64A S24479-1/16A

The following items are to be used for 2-roll operation only:

6 Incoming Guide Tube S21273-3/64 S21273-3/64 S21273-3/64 S21273-1/16
7 Idle Roll Arm Assembly S16666-035A S16666-1.0A S16666-3/64A S16666-1/16A
8 Quick Release Arm M19287 M19287 M19287 M19287
9 Latch S24299 S24299 S24299 S24299
10 Torsion Spring S24300 S24300 S24300 S24300
11 Speed Clip T10982-7 T10982-7 T10982-7 T10982-7

The following items are to be used for 4-roll operation only:

12 Incoming Guide Tube S21273-3/64F S21273-3/64F S21273-3/64F S21273-1/16F
13 Idle Roll and Shaft Assembly S24472-035A S24472-1.0A S24472-3/64A S24472-1/16A
14 Middle Guide Tube M17509-3/64 M17509-3/64 M17509-3/64 M17509-1/16

KP1682 CLUTCHED ALUMINUM DRIVE ROLL KITS

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