Lincoln Electric Welding System IM901 A User Manual
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IM901-A  
January, 2010  
LN-25™ PRO  
For use with machines having Code Number: 11387, 11388, 11507, 11508  
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 opera-  
tion 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.  
IP23  
IECꢀ60974-5  
OPERATOR’SꢀMANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
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.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
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 within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
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.  
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 spe-  
cific 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.  
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.  
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 prod-  
ucts.  
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.  
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  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
process used and properly operating  
regulators designed for the gas and  
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.  
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.  
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.  
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.  
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.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
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).  
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  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
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.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
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 cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
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.  
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.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
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SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
PRÉCAUTIONS DE SÛRETÉ  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’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 manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com  
for any updated information.  
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 your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEbꢀSITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
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:  
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.  
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TAbLE OF CONTENTS  
Page  
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Safety Precautions ...............................................................................................................A-2  
Location................................................................................................................................A-2  
High Frequency Protection...................................................................................................A-2  
Weld cable Sizes..................................................................................................................A-2  
Cable Connections...............................................................................................................A-3  
Shielding Gas Connection....................................................................................................A-3  
Wire Drive Configuration ......................................................................................................A-4  
Changing The Gun Receiver Bushing................................................................................A-4  
Procedure to Install Drive Rolls and Wire Guides ..............................................................A-4  
Pressure Arm Adjustment ....................................................................................................A-5  
Loading Spools of Wire ........................................................................................................A-5  
Gun Connections..................................................................................................................A-5  
Power Source to LN-25™ Pro Cable Connection Diagrams..................................A-6 thru A-8  
________________________________________________________________________________  
Operation.........................................................................................................................Section b  
Safety Precautions ...............................................................................................................B-1  
Graphic Symbols that appear on this Machine or in this Manual .........................................B-1  
Definition of Welding Terms .................................................................................................B-2  
General Description..............................................................................................................B-2  
Recommended Processes, Equipment Limitations, Recommended Power Sources..........B-2  
Case Front Controls ...............................................................................................B-3 thru B-5  
Internal Controls...................................................................................................................B-6  
Internal Controls Decription..................................................................................................B-7  
Constant Current Wire Welding............................................................................................B-8  
Rear Controls .......................................................................................................................B-9  
Gas Purge Pushbutton.......................................................................................................B-10  
Flow Meter..........................................................................................................................B-10  
Power-Up Sequence ..........................................................................................................B-10  
________________________________________________________________________________  
Accessories ....................................................................................................................Section C  
Factory Installed Equipment.................................................................................................C-1  
Drive Roll Kits used..............................................................................................................C-1  
Accessories Used ..................................................................................................C-2 thru C-5  
Installation of Water Cooling Kit...........................................................................................C-6  
________________________________________________________________________________  
Maintenance....................................................................................................................Section D  
Safety Precautions...............................................................................................................D-1  
Routine Maintenance ...........................................................................................................D-1  
Periodic Maintenance...........................................................................................................D-1  
Calibration Specification................................................................................................D-1,D-2  
________________________________________________________________________________  
Troubleshooting .............................................................................................................Section E  
How to Use Troubleshooting Guide .....................................................................................E-1  
Digital Display Models Error Codes......................................................................................E-2  
Troubleshooting Guide .................................................................................................E-3, E-4  
________________________________________________________________________________  
Wiring Diagram & Dimension Prints .............................................................................Section F  
________________________________________________________________________________  
Parts Pages ................................................................................................................P-557 Series  
_______________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS – LN-25™ PRO ACROSS THE ARC MODEL  
(K2613-1, K2613-2)  
INPUT VOLTAGE and CURRENT  
INPUT VOLTAGE ± 10%  
INPUT AMPERES  
4A  
15-110 VDC  
RATED OUTPUT @ 104°F (40°C)  
DUTY CYCLE  
INPUT AMPERES  
60% rating  
450  
325  
100% rating  
GEARING - WIRE FEED SPEED RANGE-WIRE SIzE  
GMAW  
FCAW  
GEARING  
WIRE SIzES  
WFS RANGE  
WFS RANGE  
WIRE SIzES  
Extra torque  
K2613-2  
.023 – 1/16"  
(0.6 – 1.6mm)  
30 – 400 ipm  
(0.8 – 10.1m/min)  
30 – 400 ipm  
(0.8 – 10.1m/min)  
.030 - 3/32”  
(10.3 – 2.4mm)  
Standard Speed  
K2613-1  
.023 – 1/16"  
(0.6 – 1.6mm)  
50 – 700 ipm  
(1.3 – 17.7m/min)  
50 – 700 ipm  
(1.3 – 17.7m/min)  
.030 - 5/64  
(0.8 - 2.0mm)  
PHYSICAL DIMENSIONS  
WIDTH  
HEIGHT  
DEPTH  
WEIGHT  
14.8 Inches  
(376 mm)  
Handle folded down  
8.7 Inches  
( 221 mm)  
22.2 Inches  
(589 mm)  
36 lbs  
(16 kg)  
TEMPERATURE RANGE  
OPERATION:  
STORAGE:  
-40°F to 104°F (-40°C to 40°C)  
-40°F to 185°F (-40°C to 85°C)  
LN-25™ PRO ACROSS THE ARC MODEL  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
The handle of the LN-25™ PRO is intended for  
moving the wire feeder about the work place only.  
WARNING  
When suspending a wire feeder, insulate the  
hanging device from the wire feeder enclosure.  
ELECTRICꢀSHOCK CAN KILL.  
• Turn the input power OFF at the  
disconnect switch or fuse box  
HIGH FREQUENCY PROTECTION  
before attempting to connect or  
disconnect input power lines, out-  
put cables or control cables.  
• Only qualified personnel should  
perform this installation.  
CAUTION  
Locate the LN-25™ PRO away from radio controlled  
machinery. The normal operation of the LN-25™  
PRO may adversely affect the operation of RF con-  
trolled equipment, which may result in bodily injury  
or damage to the equipment.  
• Do not touch metal portions of the work clip  
when the welding power source is on.  
• Do not attach the work clip to the wire feeder.  
• Connect the work clip directly to the work, as  
close as possible to the welding arc.  
• Turn power off at the welding power source  
before disconnecting the work clip from the  
work.  
----------------------------------------------------------------------------  
• Only use on power sources with open circuit  
voltages less than 110 VDC.  
WELD CAbLE SIzE  
------------------------------------------------------------------------  
LOCATION  
Table A.1 located below are copper cable sizes rec-  
ommended for different currents and duty cycles.  
Lengths stipulated are the distance from the welder to  
work and back to the welder again. Cable sizes are  
increased for greater lengths primarily for the purpose  
of minimizing cable drop.  
For best wire feeding performance, place the LN-  
25™ PRO 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 LN-25™ PRO.  
The LN-25™ PRO is rated IP23 and is suitable for  
outdoor use.  
TAbLE A.1  
RECOMMENDED CAbLE SIzES (RUbbER COVERED COPPER - RATED 167°F or 75°C)**  
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES  
AMPERES PERCENT  
DUTY  
CYCLE  
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)  
2
2
3
3
3
2
1
1
1
2/0  
1/0  
2/0  
3/0  
2/0  
2
2
2
2
2
1
1
1
1
2/0  
2/0  
2/0  
3/0  
3/0  
200  
200  
225  
225  
250  
250  
250  
250  
300  
325  
350  
400  
400  
500  
60  
100  
20  
40 & 30  
30  
40  
60  
100  
60  
100  
60  
60  
100  
60  
2
2
1
1
1
1
1
1
1
1
1/0  
2/0  
2/0  
3/0  
3/0  
3/0  
1/0  
1/0  
1/0  
1/0  
1/0  
1/0  
1/0  
1/0  
2/0  
3/0  
3/0  
4/0  
4/0  
4/0  
4 or 5  
3
3
2
1
1
1
2/0  
1/0  
2/0  
3/0  
2/0  
** 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).  
LN-25™ PRO ACROSS THE ARC MODEL  
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A-3  
A-3  
INSTALLATION  
SHIELDING GAS CONNECTION  
CAbLE CONNECTIONS  
WARNING  
There is one circular connector for the gun trigger on  
the front of the LN-25™ PRO.  
CYLINDER may explode if  
damaged.  
• Keep cylinder upright and  
chained to support.  
Function  
Wiring  
Pin  
• 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.  
5-pin trigger  
connector for  
push-guns  
only.  
Trigger  
Not used  
Common  
Not used  
Not used  
A
B
C
D
E
• 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.  
C
B
----------------------------------------------------------------------------  
Maximum inlet pressure is 100 psi. (6.9 bar.)  
E
A
D
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 out-  
let.  
4. Attach the flow regulator to the cylinder valve and  
tighten the union nut(s) securely with a wrench. Note:  
if connecting to 100% CO cylinder, insert regulator  
2
adapter between regulator and cylinder valve. If  
adapter is equipped with a plastic washer, be sure it is  
seated for connection to the CO cylinder.  
2
5. Attach one end of the inlet hose to the outlet fitting of  
the flow 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.  
8. The flow regulator is adjustable. Adjust it to the flow  
rate recommended for the procedure and process  
being used before making a weld.  
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A-4  
A-4  
INSTALLATION  
WIRE DRIVE CONFIGURATION  
(See Figure A.2)  
8. Connect the shielding gas hose to the new gun  
bushing, if required.  
9. Rotate the gun bushing until the thumb screw hole  
aligns with the thumb screw hole in the feed plate.  
Slide the gun receiver bushing into the wire drive  
and verify the thumb screw holes are aligned.  
10. Tighten the socket head cap screw.  
CHANGING THE GUN RECEIVER  
bUSHING  
WARNING  
11. Insert the welding gun into the gun bushing and  
tighten the thumb screw.  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the  
welding power source before instal-  
lation or changing drive rolls and/or  
guides.  
PROCEDURE TO INSTALL DRIVE ROLLS  
AND WIRE 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 sec-  
onds after the gun trigger is released.  
• Do not operate with covers, panels or guards  
removed or open.  
• Only qualified personnel should perform mainte-  
nance work.  
----------------------------------------------------------------------------  
Tools required:  
• 1/4" hex key wrench.  
WARNING  
• Turn the input power OFF at the  
welding power source before instal-  
lation 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 sec-  
onds after the gun trigger is released.  
• Do not operate with covers, panels or guards  
removed or open.  
Note: Some gun bushings do not require the use of  
the thumb screw.  
• Only qualified personnel should perform mainte-  
nance work.  
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.  
5. Loosen the socket head cap screw that holds the  
connector bar against the gun bushing.  
Important: Do not attempt to completely  
remove the socket head cap screw.  
6. Remove the outer wire guide, and push the gun  
bushing out of the wire drive. Because of the pre-  
cision fit, light tapping may be required to remove  
the gun bushing.  
------------------------------------------------------------------------  
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 feed plate.  
4. Rotate the triangular lock and remove the drive  
rolls.  
7. Disconnect the shielding gas hose from the gun  
bushing, if required.  
FIGURE A.2  
THUMB SCREW  
GUN RECEIVER BUSHING  
5. Remove the inner wire guide.  
OUTER WIRE GUIDE  
6. Insert the new inner wire guide, groove side out,  
over the two locating pins in the feed plate.  
7. Install a drive roll on each hub assembly secure  
with the triangular lock.  
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.  
CONNECTOR BLOCK  
SOCKET HEAD  
CAP SCREW  
LOOSEN  
TIGHTEN  
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A-5  
A-5  
INSTALLATION  
1. Squeeze the release bar on the retaining collar and  
remove it from the spindle.  
PRESSURE ARM ADJUSTMENT  
WARNING  
2. Place the spindle adapter on the spindle, aligning  
the spindle brake pin with the hole in the adapter.  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the weld-  
ing power source before installation or  
changing drive rolls and/or guides.  
• Do not touch electrically live parts.  
3. Place the spool on the spindle and align the  
adapter brake tab with one of the holes in the back  
side of the spool. An indicator mark on the end of  
the spindle shows the orientation of the brake tab.  
Be certain the wire feeds off of the spool in the  
proper direction.  
• When inching with the gun trigger, electrode  
and drive mechanism are "hot" to work and  
ground and could remain energized several sec-  
onds after the gun trigger is released.  
• Do not operate with covers, panels or guards  
removed or open.  
• Only qualified personnel should perform mainte-  
nance 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.  
4. Re-install the retaining collar. Make sure that the  
release bar snaps out and that the retaining collar  
fully engages the groove on the spindle.  
GUN CONNECTION  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the weld-  
ing power source before installation or  
changing drive rolls and/or guides.  
Set the pressure arm as follows:  
(See Figure A.3)  
Aluminum wires  
Cored wires  
Steel, Stainless wires between 4 and 6  
between 1 and 3  
between 3 and 4  
• 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 sec-  
onds after the gun trigger is released.  
• Do not operate with covers, panels or guards  
removed or open.  
FIGURE A.3  
• Only qualified personnel should perform mainte-  
nance work.  
----------------------------------------------------------------------------  
The LN-25™ PRO ACROSS THE ARC MODEL  
comes with a K1500-2 gun adapter installed. (See  
Figure A.4)  
ALUMINUM WIRES  
Al  
Fe, CrNi  
CORED WIRES  
Fe, CrNi  
STEEL, STAINLESS WIRES  
6
To install a gun,  
1. Turn power OFF.  
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.  
LOADING SPOOLS OF WIRE  
WARNING  
• Keep hands, hair, clothing and tools  
away from rotating equipment.  
• Do not wear gloves when threading wire  
or changing wire spool.  
Note: Not all gun bushings require the use of the  
thumb screw.  
• Only qualified personnel should install,  
use or service this equipment.  
FIGURE A.4  
------------------------------------------------------------------------  
Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.  
THUMB  
SCREW  
GUN  
A K468 spindle adapter is required for loading 2"  
(51mm) wide spools on 2" (51mm) spindles. Use a  
K468 spindle adapter for loading 2-1/2" (64mm) wide  
spools.  
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A-6  
A-6  
INSTALLATION  
POWER SOURCE TO LN-25™ PRO  
CAbLE CONNECTION DIAGRAMS  
ACROSS THE ARC SET-UPS  
CC Power Sources with Output Terminals Always  
Hot (See Figure A.5)  
CC Power Source  
Ranger 250, 250 LPG  
Ranger 305G, 305D  
Commander 300  
FIGURE A.5  
Vantage 300, 400, 500  
Air Vantage 500  
O
PR  
-25™  
LN  
Electrode  
Ranger10,000  
(Across the Arc)  
Ranger3 phase  
SAE 400 with CV adapter  
Work clip  
Engine Driven welder with  
Work  
Wire Feed Module  
K#  
Description  
LN-25™ PRO  
LN-25™ PRO Extra Torque  
If the power source has a Remote/Local switch, place  
the switch in the Local position.  
K2613-1  
K2613-2  
KP1695-XX  
Place the CV/CC switch in the feeder in the "CC" posi-  
tion.  
KP1696-XX  
KP1697-XX  
See Magnum Literature  
Drive Roll Kit  
Welding Gun  
CC power Source  
Welding Cables  
K1803-1  
CV Power Sources with Stud Connectors and  
Remote/Local Switch (See Figure A.6)  
FIGURE A.6  
CV-655  
LN-25™ PRO  
(Across the Arc)  
Electrode  
Work  
DC-400  
DC-600  
DC-655  
V450-Pro  
Work clip  
K#  
Description  
K2613-1  
K2613-2  
KP1695-XX  
LN-25™ PRO  
LN-25™ PRO Extra Torque  
Place the power source Remote/Local switch in the  
Local position.  
KP1696-XX  
KP1697-XX  
See magnum Literature  
Drive Roll Kit  
Place CV/CC switch in the feeder in the "CV" position.  
Welding Gun  
CV power Source  
Welding Cables  
K1803-1  
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A-7  
A-7  
INSTALLATION  
CV Power Sources with Stud Connectors and no  
Remote/Local Switch. (See Figure A.7)  
FIGURE A.7  
Jumper  
CV-400  
CV-655  
LN-25™ PR0  
(Across The Arc)  
Electrode  
Work clip  
Work  
K#  
Description  
LN-25™ PRO  
LN-25™ PRO Extra Torque  
Jumper Plug Kit  
Place CV/CC switch in the feeder in the "CV" position.  
K2613-1  
K2613-2  
KP484  
KP1695-XX  
KP1696-XX  
KP1697-XX  
See Magnum Literature  
Drive Roll Kit  
Welding Gun  
CC power Source  
Welding Cables  
K1803-1  
CV Power Source with Twist-Mate Connectors and  
Remote/Local Switch. (See Figure A.8)  
FIGURE A.8  
LN-25™ PRO  
(Across the Arc)  
Electrode  
V350-Pro  
Work clip  
Work  
K#  
Description  
Place CV/CC switch in the feeder in the "CV" position.  
K2613-1  
K2613-2  
KP1695-XX  
LN-25™ PRO  
LN-25™ PRO Extra Torque  
KP1696-XX  
KP1697-XX  
See Magnum Literature  
Drive Roll Kit  
Welding Gun  
CC power Source  
Welding Cables  
K1841  
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A-8  
A-8  
INSTALLATION  
CV Power Source with Twist-Mate Connectors and  
no Remote/Local Switch. (See Figure A.9)  
FIGURE A.9  
Jumper  
CV-250  
CV-300  
CV-305  
LN-25™ PRO  
Electrode  
Work clip  
Work  
K#  
Description  
LN-25™ PRO  
LN-25™ PRO Extra Torque  
Place CV/CC switch in the feeder in the "CV" position.  
K2613-1  
K2613-2  
KP1695-XX  
KP1696-XX  
KP1697-XX  
See Magnum Literature  
Drive Roll Kit  
Welding Gun  
CV power Source  
Welding Cables  
Jumper Plug kit  
K1841-  
K484  
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b-1  
b-1  
OPERATION  
GRAPHIC SYMbOLS THAT APPEAR ON  
THIS MACHINE OR IN THIS MANUAL  
SAFETY PRECAUTIONS  
READ AND UNDERSTAND ENTIRE SECTION  
bEFORE OPERATING MACHINE.  
INPUT POWER  
ON  
WARNING  
• ELECTRIC SHOCK CAN KILL.  
Unless using COLD FEED fea-  
ture, when feeding with gun trig-  
ger, the electrode and drive  
mechanism are always electri-  
cally energized and could  
remain energized several sec-  
onds after the welding ceases..  
• Do not touch electrically live part or electrode  
with skin or wet clothing.  
• Insulate yourself from work and ground.  
• Always wear dry insulating gloves.  
• Do not operate with covers, panels or guards  
removed or open.  
-------------------------------------------------------------------------  
• FUMES AND GASSES can be  
dangerous.  
OFF  
WIRE FEEDER  
POSITIVE OUTPUT  
NEGATIVE OUTPUT  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
INPUT POWER  
-------------------------------------------------------------------------  
• WELDING SPARKS can cause  
fire or explosion.  
DIRECT CURRENT  
• Keep flammable material away.  
OPEN CIRCUIT  
VOLTAGE  
U
0
-------------------------------------------------------------------------  
ARCꢀRAYS can burn.  
• Wear eye, ear and body protec-  
tion.  
U
INPUT VOLTAGE  
OUTPUT VOLTAGE  
INPUT CURRENT  
1
2
-------------------------------------------------------------------------  
SEE ADDITIONAL WARNING INFORMATION  
UNDER ARC WELDING SAFETY PRECAUTIONS  
AND IN THE FRONT OF THIS OPERATING MAN-  
UAL.  
U
-------------------------------------------------------------------------  
I
1
I
OUTPUT CURRENT  
2
PROTECTIVE  
GROUND  
WARNING OR  
CAUTION  
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b-2  
b-2  
OPERATION  
General Functional Description  
DEFINITION OF WELDING TERMS  
The LN-25™ PRO as designed is a simple, robust  
feeder. Standard features include a calibrated wire  
feed speed dial, 2 step/trigger interlock switch, CV-CC  
switch, Gas Purge and Cold Feed.  
WFS  
• Wire Feed Speed  
CC  
• Constant Current  
RECOMMENDED PROCESSES  
• GMAW  
• FCAW  
CV  
• Constant Voltage  
GMAW  
• Gas Metal Arc welding  
PROCESS LIMITATIONS  
• GMAW-P procedures must be qualified by the cus-  
tomer.  
• Across-the-Arc models are not recommended for  
stitch or spot welding.  
SMAW  
• Shielded Metal Arc welding  
FCAW  
• Flux Core Arc Welding  
EQUIPMENT LIMITATIONS  
• The duty cycle of the wire feeder is 325A, 100% and  
450A, 60%. Duty cycle is based upon the amount of  
welding performed in a 10 minute period.  
• The maximum spool size is 45 lb, 12" diameter.  
• Maximum FCAW gun length is 15 ft.  
• Maximum GMAW gun length is 25 ft.  
GENERAL DESCRIPTION  
General Physical Description  
The LN-25™ PRO is specially engineered to be the  
most rugged portable wire feeder available.  
• Push-pull guns do not work with the wire feeder.  
• When using the digital meter kit, preset voltage is  
accurate only with the following power sources:  
Several models of the LN-25™ PRO are offered to  
best meet individual welder needs. The Extra Torque  
model features additional torque gearing for reliable  
feeding of large diameter FCAW wires. All of the mod-  
els include a gas solenoid and flow meter for the flexi-  
bility to run most wire processes.  
Invertec V-350  
Invertec V-450  
DC-400  
CV-305  
CV-400  
DC-600  
DC-655  
The plastic case is molded from a high impact, flame  
retardant plastic for durability and low weight. The  
patent pending design keeps the internal components  
protected and dry.  
RECOMMENDED POWER SOURCES  
• CV-250  
• CV-300  
• CV-305  
• CV-400  
• CV-655  
• DC-400  
• Ranger 3 Phase  
• Ranger GXT  
• Ranger 250  
• Ranger 305  
• SAE-400  
• Pipeliner 200G  
• Classic 300  
• Vantage 300  
• Vantage 400  
• Vantage 500  
• Air Vantage 500  
The heart of the LN-25™ PRO is the 2 roll MAX-  
TRAC™ 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 patent pending drive rolls  
for smooth, steady feeding without slippage.  
• DC-600  
• DC-655  
• Invertec V-350 PRO  
• Invertec V-450 PRO  
• Multi-Weld 350  
• Ranger 10,000  
With only one p.c. board, the LN-25™ PRO is  
designed to be simple, reliable and easy to service.  
The p.c. board is mounted with Lincoln’s leading envi-  
ronmental design protection by mounting the board in  
a plastic tray and potting it with epoxy.  
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b-3  
b-3  
OPERATION  
(See Customer Assistance Policy in the front of this  
Instruction Manual)  
CASE FRONT CONTROLS (See Figure b.1)  
FIGURE b.1  
1
5
6
2
3
4
ITEM  
DESCRIPTION  
1
2
3
4
5
6
Analog Voltmeter  
Wire Feed Speed Knob  
5-pin gun trigger connector  
Work sense lead  
Thermal LED, Motor Overload  
Polarity LED  
1. ANALOG VOLTMETER  
The analog voltmeter shows the voltage between  
electrode and work. On across the arc models, the  
voltmeter shows open circuit voltage when the wire  
feeder is not welding. The voltmeter is polarity  
insensitive and the range is 0 – 40VDC.  
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b-4  
b-4  
OPERATION  
2. WIRE FEED SPEED KNOb  
Wire Feed Speed, CC Operation  
The large, calibrated wire feed speed knob makes  
for easy and accurate adjustment of the wire feed  
speed. The knob rotates 3/4 turn. Turn the knob  
clockwise to increase the wire feed speed, and  
counter clockwise to reduce the wire feed speed.  
When Across the Arc models are operated with CC  
power sources, the wire feed speed changes as the  
arc voltage changes. When the arc voltage increases,  
the wire feed speed will increase; and when the arc  
voltage decreases, the wire feed speed will decrease.  
Models with analog voltmeters have a calibrated  
scale printed around the wire feed speed knob  
using "in/min" units. A separate decal with "m/min"  
units is included with these models wire feeder.  
To preset the wire feed speed on CC power sources:  
1. Set the Wire Feed Mode switch inside the LN-  
25™ Pro to "CC".  
Wire Feed Speed, CV Operation  
2. Refer to the Figure B.1a graph for the setting for  
the wire feed speed knob setting. Select the hori-  
zontal line representing the Desired Wire Feed  
Speed. (See Figure B.1a arrow for 375 in/min.)  
3. Select the diagonal line representing the Arc  
Volts. (See Figure B.1a for 29 volts.)  
4. Determine the vertical line representing the CC  
representing the CC Wire Feed Speed setting  
where the above two lines cross. (See Figure  
B.1a arrow line for 450.) Set the LN-25™ Pro  
wire feed speed knob to this value.  
When Across the Arc models are operated with CV  
power sources, the wire feed speed will remain a con-  
stant value, independent of arc voltage changes, as  
along as the arc voltage does not drop below the val-  
ues per the following table.  
CV OPERATION  
Maximum WFS Maximum WFS  
Standard Spin (Extra Torque  
Minimum Arc Volts  
CC WFS dial setting = desired WFS x 35  
Arc Volts  
Example:  
375 in/min. (Horizontal Line) x 35  
Gearing  
280  
340  
Gearing)  
210  
235  
15 V  
17 V  
21 V  
24 V  
27 V  
=
29 Arc Volts (Diagonal Line)  
440  
520  
400  
400  
= 452.5 (Vertical Line) Use 450 setting  
(See Figure B.1a)  
600  
400  
FIGURE b.1a  
1
50  
    1
                      5
         2
50  
5
    4
50  
    5
50  
         6
6
         7
4
25  
6
3
LO  
TS  
35  
33  
31  
29  
27  
25  
23  
21  
19  
17  
15  
700  
650  
600  
550  
500  
450  
ARC  
VOLTS  
A constant voltage (CV) power  
source is recommended for flux-  
cored arc welding. (FCAW) and  
gas metal arc welding (GMAW) to  
obtain code quality results.  
However, this wire feeder may also  
be used with a constant current  
(CC) power source to obtain pass-  
able results for noncritical quality  
applications.  
400  
375  
350  
300  
250  
200  
150  
100  
50  
50 100 150 200 250 300 350 400 450 500 550 600 650 700  
CC  
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b-5  
b-5  
OPERATION  
3. 5-PIN GUN TRIGGER CONNECTOR  
4. WORK SENSE LEAD  
5. THERMAL LED, MOTOR OVERLOAD  
The thermal light illuminates when the  
wire drive motor draws too much current.  
If the thermal light illuminates, the wire  
drive will automatically shutdown for up to  
30 seconds to allow the motor to cool. To  
start welding again, release the gun trigger, inspect  
the gun cable, liner (and conduit). Clean and make  
repairs as necessary. Start welding again when the  
problem has been safely resolved.  
For best results, keep the gun cable and conduit as  
straight as possible. Perform regular maintenance  
and cleaning on the gun liner, conduit and gun.  
Always use quality electrode, such as L-50 or L-56  
from Lincoln Electric.  
6. POLARITY LED  
The Polarity LED  
-
POLARITÉ  
POLARDAD  
POLARITY  
+
lights when the wire  
feeder is connected  
for positive polarity.  
Use the polarity  
LED to verify the  
+ POLARITY  
POLARDAD  
- POLARITÉ  
wire feeder is connected for the proper polarity.  
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b-6  
b-6  
OPERATION  
INTERNAL CONTROLS  
FIGURE b.2  
5
4
6
3
2
1
8
7
12  
10  
11  
9
ITEM  
DESCRIPTION  
1
2
3
4
5
2 Step Trigger Interlock Switch  
CV / CC Switch  
Pressure Adjustment Arm  
Optional Timer Kit (See Accessories Section)  
Spool Retainer  
6
Spindle Brake  
7
8
Gun Bushing  
Thumb Screw for securing the welding Gun  
9
Socket Head Cap Screw for securing the Gun Bushing  
10  
11  
12  
Drive Hubs  
Inlet Wire Guide  
Cold Feed Pushbutton  
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b-7  
b-7  
OPERATION  
CV/CC SWITCH  
(See Figure B.2)  
INTERNAL CONTROLS DESCRIPTION  
(See Figure B.2)  
CV  
CC  
The CV/CC switch sets the wire  
feed speed control method for the  
wire feeder.  
2 Step - Trigger Interlock Switch  
CC  
CV  
The 2 Step - Trigger Interlock  
switch changes the function of the  
gun trigger. 2 Step trigger opera-  
tion turns welding on and off in  
direct response to the trigger.  
Trigger Interlock operation allows  
welding to continue when the trig-  
ger is released for comfort on long  
welds.  
In the CV position, the wire feed  
speed remains constant during  
welding. A steady arc voltage is  
regulated by the power source by  
adjusting the arc current.  
In the CC position, the wire feed  
speed varies during welding. The  
arc length is maintained by chang-  
ing the wire feed speed.  
Place the toggle switch in the DOWN position for 2  
Step operation or in the UP position for Trigger  
Interlock operation.  
COLD FEED PUSHbUTTON  
(See Figure B.2)  
2 Step Trigger  
When cold feeding, the wire  
drive will feed electrode but  
neither the power source nor  
the gas solenoid will be ener-  
gized. Adjust the speed of  
cold feeding by rotating the  
WFS knob. Cold feeding, or  
"cold inching" the electrode is  
useful for threading the elec-  
trode through the gun.  
2 Step trigger operation is the most common. When  
the gun trigger is pulled, the welding power source  
energizes the electrode output and the wire feeder  
feeds wire for welding. The power source and wire  
feeder continue welding until the trigger is released.  
Trigger Interlock  
Trigger Interlock operation provides for operator com-  
fort when making long welds. When the gun trigger is  
first pulled, the welding power source energizes the  
output and the wire feeder feeds wire for welding.  
The gun trigger is then released while the weld 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 feed-  
ing wire.  
CAUTION  
If the arc goes out while welding with  
trigger interlock operation, the elec-  
trode 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 released.  
----------------------------------------------------------------------------  
LN-25™ PRO ACROSS THE ARC MODEL  
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b-8  
b-8  
OPERATION  
CONSTANT CURRENT WIRE WELDING  
(See Figure B.3)  
If the contact tip to work distance is properly main-  
tained, a satisfactory operating voltage range may be  
achieved, and a sound weld may result. However,  
when a welder uses a longer contact tip to work dis-  
tance, an arc-sensing wire feeder compensates by  
increasing the wire feed speed to regulate the voltage.  
Even if the voltage and current remain unchanged, the  
increased wire feed speed may result in a deposition  
rate well beyond the specified range of the electrode.  
Under these conditions, the specified weld metal prop-  
erties may not be achieved.  
Most semiautomatic welding processes perform better  
using constant voltage power sources.  
Welding codes usually do not address the power  
source selection or specifically, whether the welding  
process is to be operated in the constant voltage or  
constant current mode. Instead, codes typically speci-  
fy limitations on the current, voltage, heat input and  
preheat temperature based on the material to be  
welded. The intention is to assure that proper weld  
material properties will develop.  
Constant voltage power sources deliver large current  
surges to stabilize the arc when the electrode is short-  
ed or the arc length is very short. However, a constant  
current power source does not provide such a  
response to stabilize the arc. It may be difficult to  
achieve required weld metal properties, or to achieve  
the required quality of welds needed to pass nonde-  
structive tests, when such welds are made under con-  
stant current operation.  
Welding is sometimes performed using constant cur-  
rent power sources. The operation can be more con-  
venient because it may allow the use of an existing  
stick (SMAW) power source and the power source  
can be placed at a distant location without any provi-  
sion for adjusting the output settings.  
For constant current operation, the power source is  
set to deliver the specified current. The power source  
regulates this current regardless of changes in the  
welding circuit, including cable length, electrode diam-  
eter, wire feed speed, contact tip to work distance,  
etc.  
For these reasons, Lincoln Electric does NOT recom-  
mend constant current semiautomatic welding for  
applications which need to meet specified weld metal  
chemical or mechanical property requirements or weld  
quality requirements.  
Changes in the wire feed speed (WFS) or contact tip  
to work distance (CTWD) affect the arc voltage when  
constant current power sources are used. Lowering  
the wire feed speed raises the voltage, raising the  
wire feed speed lowers the voltage. Lengthening the  
contact tip to work distance raises the voltage, short-  
ening the contact tip to work distance lowers the volt-  
age.  
FIGURE b-3  
Current  
Wire  
Feeder  
+
-
CTWD  
WFS  
Constant Current  
Power Source  
Current  
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b-9  
b-9  
OPERATION  
REAR CONTROLS:  
4
S
l
iel  
o
or de Lead  
nal  
n
    g
  r
    e
    r
    c
    o
    o
    l
      e
      d
g
un  
ITEM  
6
D
E
S
C
R
I
  T
  I
N
5
4
2
1
1
2
3
4
5
6
ITEM  
DESCRIPTION  
1
2
3
4
Gas Purge Pushbutton  
Flow Meter Ball  
Flow Meter Valve  
Shielding Gas Inlet  
5
6
Electrode Lead  
Optional Water cooled gun  
connections  
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b-10  
b-10  
OPERATION  
GAS PURGE PUSHbUTTON  
POWER-UP SEQUENCE  
The gas solenoid valve will energize but neither the  
power source output nor the drive motor will be turned  
on. The Gas Purge switch is useful for setting the  
proper flow rate of shielding gas. Flow meters should  
always be adjusted while the shielding gas is flowing.  
On feeders with analog voltmeters, the thermal LED  
will briefly light during power-up.  
If the gun trigger is activated during power up, the  
feeder will not operate until the gun trigger is released.  
FLOW METER  
The flowmeter shows the flow rate of shielding gas  
and has a valve to adjust the flow. The flow meter is  
scaled for CO , Ar, and Ar/CO blends. The middle of  
2
2
the ball indicates the flow rate of shielding gas.  
Adjust the flow rate while depressing the GAS  
PURGE switch by turning the valve at the bottom of  
the meter. Most weld procedures require 25-40 scfh  
(11.8 - 18.9 lpm) for sufficient shielding gas coverage.  
Gun angle, nozzle diameter, joint configuration and  
wind conditions may effect the amount of shielding  
gas required.  
When using a wire feeder with  
a flow meter, adjust the regu-  
lator at the shield gas bottle or  
supply to a flow rate that is  
higher than the flow rate indi-  
cated on the feeder flow  
meter. Note that most regula-  
tors are calibrated based upon  
having low restrictions on the  
outlet. The valve on the feeder  
flow meter creates a high  
90  
80  
70  
60  
50  
restriction and may cause  
errors in the readings at the  
40  
Ball  
30  
20  
supply regulator. Set the gas  
flow rate using the feeder flow  
10  
meter reading and not the  
supply regulator reading.  
Valve  
SCFH  
10  
20  
Liter/Min.  
4.7  
9.4  
30  
40  
50  
60  
70  
80  
14.2  
18.9  
23.6  
28.3  
33.1  
37.8  
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C-1  
C-1  
ACCESSORIES  
FACTORY INSTALLED EQUIPMENT  
• K1500-2 Gun Receiver Bushing.  
DRIVE ROLL KITS  
KP KIT  
WIRE TYPE  
Steel Wires:  
ELECTRODE SIzE  
.023-.030 (0.6-0.8mm)  
.035 (0.9mm)  
KP1696-030S  
KP1696-035S  
KP1696-045S  
KP1696-052S  
Includes: 2 V groove  
drive rolls and inner  
.045 (1.2mm)  
.052 (1.4mm)  
1/16 (1.6mm)  
.035,.045 (0.9, 1.2mm)  
.040 (1.0mm)  
KP1696-1/16S wire guide.  
KP1696-1  
KP1696-2  
.030-.035" (0.8-0.9mm) KP1697-035C  
.040-.045" (1.0-1.2mm)  
.052" (1.4mm)  
1/16" (1.6mm)  
.068-.072" (1.7-1.8mm)  
5/64" (2.0mm)  
3/32” (2.4mm)  
KP1697-045C  
KP1697-052C  
KP1697-1/16C  
KP1697-068  
KP1697-5/64  
KP1697-3/32  
KP1695-035A  
KP1695-040A  
KP1695-3/64A  
KP1695-1/16A  
Cored Wires:  
Includes: 2 Knurled  
drive rolls and inner  
wire guide.  
.035" (0.9 mm)  
.040" (1.0mm)  
3/64" (1.2mm)  
Includes: 2 polished  
U groove drive rolls,  
outer wire guide and  
inner wire guide.  
Aluminum Wires:  
1/16" (1.6mm)  
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C-2  
C-2  
ACCESSORIES  
K1796-xx  
AWG 1/0 Co-Axial Power Cable  
AWG #1 Coaxial Power Cable  
Work and Feeder Cables Package  
Includes: 1/0 Coaxial weld  
cable of length "xx". Ends of  
the weld cable have lug con-  
nections. Use for Pulse weld-  
ing.  
K2593-xx  
K1803-1  
Includes: AWG #1 Coaxial  
weld cable of length "xx".  
Ends of the weld cable have  
lug connections. Use for  
Pulse or STT™ welding.  
Includes: Twist-Mate to Lug  
2/0 cable 14' (1.2m) long with  
Ground Clamp, and Twist-  
Mate to Lug 2/0 Cable 9'  
(2.7m) long.  
K1840-xx  
K1842-xx  
Weld Power Cable, Twist-Mate to  
Lug  
Includes: Twist-Mate to Lug,  
1/0 cable of length "xx".  
IIncludes: Lug to Lug, 3/0  
Cable of length "xx" for lengths  
up to 60' (18.3m). Lug to Lug,  
4/0 Cable of length "xx" for  
lengths greater than 60'  
(18.3m).  
Weld Power Cable, Lug to Lug  
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C-3  
C-3  
ACCESSORIES  
Includes: 14 pin to 14 pin wire  
feeder to power source control  
cable.  
Control Cable  
K1797-xx  
Includes: Adapter control  
cable for connecting a Lincoln  
42 VAC wire feeder to a 24  
VAC Miller power source.  
Requires the digital  
Adapter for Competitive Power  
Sources  
K2335-1  
meter/remote voltage control  
kit.  
Includes: 14 pin circular con-  
nector with jumper for leads 2-  
4. For use in power sources  
for turning the weld terminals  
"ON" at all times.  
Jumper Plug Kit  
K484  
Includes: One transformer kit  
for operating a 42 VAC wire  
feeder on a power source sup-  
plying only 115 VAC.  
K1520-1  
(requires Digital  
Meter/remote  
control kit)  
42 Volt Transformer Kit  
K1798  
(requires  
remote control  
kit  
Adapter Cable for Control Cable to Includes: 14 circular connector  
Terminal Strip Power Sources  
with leads to connect to a ter-  
minal strip.  
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C-4  
C-4  
ACCESSORIES  
K910-1  
Ground Clamp  
Includes: One 300 Amp  
Ground Clamp.  
K910-2  
Ground Clamp  
Includes: One 500 Amp  
Ground Clamp.  
Gun Receiver Bushing (for guns  
with K466-1 Lincoln gun connec-  
tors; Innershield and Subarc guns)  
Includes: Gun receiver bush-  
ing, set screw and hex key  
wrench.  
K1500-1  
Gun Receiver Bushing (for guns  
with K466-2, K466-10 Lincoln gun Includes: Gun receiver bush-  
connectors; Magnum 200/300/400 ing with hose nipple, set screw  
K1500-2  
guns and compatible with Tweco®  
#2-#4)  
and hex key wrench.  
Gun Receiver Bushing (for guns Includes: Gun receiver bush-  
with K613-7 Lincoln gun connec- ing with hose nipple, set screw  
K1500-3  
tors; Magnum 550 guns and com-  
patible with Tweco® #5)  
and hex key wrench.  
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C-5  
C-5  
ACCESSORIES  
Gun Receiver Bushing (for gun Includes: Gun receiver bush-  
with K466-3 Lincoln gun connec- ing with hose nipple, set screw  
K1500-4  
K1500-5  
K489-7  
tors; compatible with Miller® guns.)  
and hex key wrench.  
Includes: Gun receiver bushing  
Gun Receiver Bushing (compatible with hose nipple, 4 guide tubes,  
with Oxo® guns.) set screw and hex key wrench.  
Gun Receiver Bushing (for Lincoln Includes: Gun receiver bushing  
Fast-Mate guns.) with trigger connector.  
K435  
K468  
Spindle Adapter, for mounting 14 Includes: Spindle Adapter made  
lb. (6.4 kg) Innershield Coils on 2  
in (51 mm) spindles.  
from 2 coil retainers. (Electrode  
not included.)  
Spindle Adapter, for mounting 8in  
(203mm) diameter spools on 2 in  
(51 mm) spindles.  
Includes: 2 Spindle Adapters,  
one for 2" wide spools and the  
other for 3" wide spools.  
Includes: 2 hoses with female  
quick connectors at each end, 2  
male connectors for 3/16" ID  
hose, 2 male connectors for _" ID  
hose, and mounting hardware.  
Water Connection Kit (for  
European and Control cable mod-  
els only)  
K590-6  
K586-1  
Includes: Deluxe Gas Regulator  
for Mixed Gases, Adapter for  
CO2 and 10' (3.0m) Hose.  
Deluxe Adjustable Gas Regulator  
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C-6  
C-6  
ACCESSORIES  
4. Use a 5/16" nut driver to remove the screws holding  
the water cooling cover on the case front of the  
inner module and on the rear of the case.  
INSTALLATION OF THE K590-6 WATER  
COOLING KIT  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the dis-  
connect switch before working on  
this equipment.  
• Do not touch electrically hot parts.  
• Only qualified personnel should  
install, use or service this equipment.  
------------------------------------------------------------------------  
The K590-6 components are rated up to 70 psi (5 bar)  
and 158°F (70°C). Use a coolant fluid that is compati-  
ble with the water cooler and the gun.  
5. Install the fitting and hose assembly to the case  
front. Route the hoses along the bottom of the  
inner module and out through the cutout of the  
cover. Slide the module back into the case.  
Tools required:  
• 3/8" wrench  
• 5/16" nut driver  
• medium flat bladed screw driver  
• cutting tool  
1. Turn power off at the welding power source.  
2. Remove the screws securing the case to the inner  
module using a 3/8" wrench.  
6. Secure the module to the case with the screws.  
(Shown in Step 2)  
7. Install the fitting assembly to the rear of the case  
3. Remove the module from the case by lifting the  
front of the module approximately .25" (6 mm) and  
then sliding forward.  
ALUMINUM CASE  
PLASTIC CASE  
8. Slide the hose clamps on to the hoses. Trim the  
hoses to length so that they lay flat on the case bot-  
tom. Slide hose clamps on the hose. Slide the  
hoses on to the fittings on the case rear and secure  
with the hose clamps.  
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D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
5. Energize the output circuit of the power source.  
Adjust the power source output to 20±1 VDC as  
measured on the reference meter.  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the  
6. Verify that LN-25™ PRO voltmeter reads between  
19 and 21 volts.  
welding power source before  
installation or changing drive  
rolls and/or guides.  
•Do not touch electrically live  
parts.  
If the voltmeter reading is out of range, check for  
loose connections or replace the voltmeter. There is  
no calibration adjustment for the LN-25™ PRO volt-  
meter.  
• 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.  
Flow Meter Validation  
Tools required:  
• Only qualified personnel should perform main-  
tenance work.  
----------------------------------------------------------------------  
ROUTINE MAINTENANCE  
• Flow meter reference standard.  
• Constant voltage DC welding power source (DC-  
400, V-350, CV-400 or equivalent).  
To verify the flow meter accuracy:  
1. Turn power OFF.  
• Check weld cables, control cables and gas hoses  
for cuts.  
• Clean and tighten all weld terminals.  
2. Connect the LN-25™ PRO to the constant voltage  
DC welding power source. The work lead of the  
LN-25™ PRO must be connected to the work ter-  
minal of the power source.  
PERIODIC MAINTENANCE  
• Clean drive rolls and inner wire guide and replace if  
worn.  
• Blow out or vacuum the inside of the feeder.  
3. Connect a supply of CO2 to the wire feeder. Do  
not exceed the maximum inlet pressure of the wire  
feeder.  
CALIbRATION SPECIFICATION  
4. Disconnect the shielding gas hose that connects to  
the gun bushing.  
Voltmeter Validation, Across the Arc Analog Meter  
Models  
5. Connect the shielding gas hose to flow meter refer-  
ence standard.  
Tools required:  
• DC voltmeter reference standard  
• Constant voltage DC welding power source with  
adjustable no-load voltage (DC-400, V-350, CV-400  
or equivalent).  
6. Orient the LN-25™ PRO in a vertical position.  
7. Turn power ON.  
To verify the analog voltmeter accuracy:  
1. Turn power OFF.  
8. Adjust the flow meter on the LN-25™ PRO to 40  
scfh while pressing the GAS PURGE button.  
2. Connect the LN-25™ PRO ACROSS THE ARC  
MODEL to the constant voltage DC welding power  
source. The work lead of the LN-25™ PRO must  
be connected to the work terminal of the power  
source.  
9. Measure the gas flow with the calibrated flow  
meter while pressing the GAS PURGE button.  
10. The measured flow rate should be between 35  
and 45 scfh.  
3. Connect the reference voltmeter between the  
brass block of the LN-25™ PRO and the work  
lead.  
4. Turn power ON.  
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D-2  
D-2  
MAINTENANCE  
The LN-25™ PRO flow meter cannot be calibrated. If  
the flow meter reads incorrectly, check for leaks or  
kinks in the gas hose. Replace the flow meter if neces-  
sary.  
To change the wire feed speed calibration:  
(See Figure D.2)  
Wire Feed Speed Validation  
Tools required:  
• 5/16" nut driver  
• RPM meter  
(See Figure D.1)  
Calibration of the LN-25™ PRO may be required when  
the p.c. board, wire feed speed potentiometer or motor is  
replaced or serviced. Calibration matches the scale on  
the name plate to the actual wire feed speed.  
• Shorting plug. The shorting plug shorts pins 4 & 8 of  
connector J3 on the Control P.C. Board. J3 is a 8 pin  
molex connector.  
1. Turn power OFF.  
Tools required:  
• RPM meter  
2. Remove the 4 screws holding the rear cover inside  
the feeder and remove the cover.  
• Constant voltage DC welding power source (DC-400,  
V-350, CV-400 or equivalent)  
• 7/16" open end wrench  
3. Open the idle arm.  
To verify if calibration is necessary:  
1. Turn power OFF.  
4. Set the wire feed speed per the table.  
Model gearing Wire Feed Speed  
Standard Speed 400 in/min  
2. Set the wire feed speed per the table.  
Model gearing Wire Feed Speed Acceptable Range  
Extra Torque  
150 in/min  
5. Connect the LN-25™ PRO to the constant voltage DC  
welding power source. The work lead of the LN-25™  
PRO must be connected to the work terminal of the  
power source.  
Standard Speed 400 in/min  
Extra Torque 150 in/min  
69 - 77 rpm  
25 - 31 rpm  
3. Remove the plastic cover from the lower portion of the  
wire drive with a 7/16" wrench.  
6. Turn power ON.  
4. Connect the LN-25™ PRO to the constant voltage DC  
welding power source. The work lead of the LN-25™  
PRO must be connected to the work terminal of the  
power source.  
7. Insert the shorting plug into connector J3 on the  
Control P.C. Board. The shorting plug shorts pins 4  
& 8.  
8. Remove the shorting plug.  
5. Turn power ON.  
9. Turn power OFF.  
6. Measure the motor rpm when the COLD FEED button  
is pressed.  
10. Replace the cover and secure with the screws.  
7. Verify the rpm is within the acceptable range.  
FIGURE D.2  
COVER  
FIGURE D.1  
MOTOR  
SHAFT  
COVER  
P.C. bOARD  
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E-1  
E-1  
TROUbLESHOOTING  
HOW TO USE TROUbLESHOOTING GUIDE  
WARNING  
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.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
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.  
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
WARNING  
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.  
• Welding power source must be connected to system ground per the National Electrical  
Code or any applicable local codes.  
• Only qualified personnel should perform maintenance work.  
CAUTION  
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.  
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E-2  
E-2  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Digital Display Models Error Codes  
Description  
Possible Adjustments  
Fault Code  
1. The wire drive motor has over- 1. Check that the electrode slides  
Err 81 Motor overload, long term.  
heated.  
easily through the gun and cable.  
2. Remove tight bends from the gun  
and cable.  
3. Check that the spindle brake is  
not too tight.  
4. Verify a high quality electrode is  
being used.  
5. Wait for the error to reset and the  
motor to cool (approximately 1  
minute).  
1. The wire drive motor current draw 1. Check that motor can turn freely  
has exceeded limits, usually when idle arm is open.  
Err 82 Motor overload, short term.  
because the motor is in a locked 2. Verify that the gears are free of  
rotor state.  
debris and dirt.  
CAUTION  
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.  
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E-3  
E-3  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Output Problems  
The feeder does power up - no dis- 1. The work sense lead is discon-  
1. Connect the work sense lead to  
the work in a location free of dirt,  
rust and paint.  
2. Turn ON the power source.  
3. Reset the circuit breakers.  
play, no cold feed.  
nected or is a poor electrical con-  
nection. (Across the arc models)  
2. The power source is OFF.  
3. The circuit breaker for the wire  
feeder on power source have  
tripped. (control cable models)  
4. The control cable may be loose or  
damaged. (control cable models)  
4. Tighten, repair or replace the con-  
trol cable.  
The wire feeder power up but there 1. The contactor coil connections are  
is no output when the trigger is loose.  
pulled. The shielding gas is flowing 2. The contactor has failed.  
and the drive rolls turn.  
1. Verify the contactor coil connec-  
tions.  
2. Replace the contactor.  
No shielding gas.  
1. The gas supply is OFF or empty.  
2. The gas hose is cut or crushed  
1. Verify the gas supply is ON and  
flowing.  
2. Route the gas hose so it avoids  
sharp corners and make sure  
nothing is on top of it. Repair or  
replace damaged hoses.  
3. The flow meter valve is closed.  
4. Dirt or debris is in the solenoid.  
3. Open the flow meter valve.  
4. Apply filtered shop at 80psi to the  
solenoid to remove dirt.  
5. There is a loose solenoid connec-  
tion.  
5. Remove the cover and check that  
all connections are in good condi-  
tion.  
6. The solenoid has failed.  
Inconsistent wire feeding or wire not 1. The gun cable is kinked and/or  
feeding but drive rolls turning.  
1. Keep the gun cable as straight as  
possible. Avoid sharp corners or  
bends in the cable.  
twisted  
2. The wire is jammed in the gun and  
cable.  
2. Remove the gun from the wire  
feeder and pull the jammed wire  
out of the gun and cable.  
3. The gun liner is dirty or worn.  
4. The electrode is rusty or dirty.  
3. Blow dirt out of the liner with low  
pressure (40psi or less). Replace  
the liner if worn.  
4. Use only clean electrode. Use  
quality electrode, like L-50 or L-56  
from Lincoln Electric.  
5. The contact tip is partially melted  
or has spatter.  
5. Replace the contact tip.  
6. Improper gun liner, tip, drive rolls  
and/or inner wire guide.  
6. Verify the proper parts are  
installed.  
CAUTION  
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.  
LN-25™ PRO ACROSS THE ARC MODEL  
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E-4  
E-4  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Output Problems  
7. Incorrect tension arm pressure on 7. Adjust the tension arm per the  
the drive rolls.  
Instruction Manual. Most elec-  
trodes feed well at a tension arm  
setting of "3".  
8. The spindle brake is too tight.  
9. Worn drive roll  
8. Verify the spool of wire moves  
with minimal effort.  
9. Replace the drive rolls if worn or  
filled with dirt.  
Wire feed speed consistently oper-  
ates at the wrong value. The speed  
changes when the wire feed speed  
knob is adjusted.  
1. The jumper lead for normal 1. Properly connect the normal  
speed/extra torque is connected  
improperly.  
2. The wrong gear is installed in the the wire drive.  
speed/extra torque jumper.  
2. Install the proper pinion gear in  
wire drive.  
3. Replace the motor/gearbox  
3. The brushes on the motor are assembly.  
worn.  
The wire feed speed stuck at 200-  
300 in/min and there is no change  
when the wire feed speed knob is  
adjusted.  
1. The tachometer is connected 1. Verify all of the tachometer leads  
improperly.  
2. The tachometer has failed.  
are properly connected.  
2. Replace the motor and tachome-  
ter assembly.  
Variable or "hunting" arc.  
1. Wrong size, worn and/or melted 1. Replace the contact tip.  
contact tip.  
2. Worn work cable or poor work 2. Verify all work and electrode con-  
connection.  
nections are tight and that the  
cables are in good condition.  
Clean/replace as necessary.  
3. Adjust polarity to the recommend-  
ed procedure.  
3. Wrong polarity.  
4. The gas nozzle is extended 4. Adjust the gas nozzle and shorten  
beyond the contact tip or the wire the stickout to 3/8 to 1/2 inches.  
stickout is too long.  
5. Poor gas shielding on processes 5. Check gas flow and mixture.  
requiring gas.  
Remove or block sources of  
drafts.  
(Digital display models)  
When the trigger is pulled, the wire  
feeds slowly.  
1. The Run-In switch is "ON"  
1. Use the set-up Push-button to turn  
Run-in OFF.  
Poor arc starts with sticking or  
"blast-offs", weld porosity, narrow  
and ropy looking bead.  
1. Improper procedures or tech- 1. See "Gas Metal Arc Welding  
niques. Guide" (GS-100)  
CAUTION  
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.  
LN-25™ PRO ACROSS THE ARC MODEL  
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F-1  
F-1  
DIAGRAMS  
LN-25™ PRO ACROSS THE ARC MODEL  
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F-2  
F-2  
DIAGRAMS  
LN-25™ PRO ACROSS THE ARC MODEL  
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F-3  
F-3  
DIMENSION PRINT  
LN-25™ PRO ACROSS THE ARC MODEL  
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NOTES  
LN-25™ PRO ACROSS THE ARC MODEL  
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•
•
Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
•
•
Keep flammable materials away.  
•
•
Wear eye, ear and body protection.  
WARNING  
Spanish  
•
No toque las partes o los electrodos  
bajo carga con la piel o ropa moja-  
da.  
Mantenga el material combustible  
fuera del área de trabajo.  
Protéjase los ojos, los oídos y el  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
•
•
Aislese del trabajo y de la tierra.  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Isolez-vous du travail et de la terre.  
•
•
Gardez à l’écart de tout matériel  
inflammable.  
•
•
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
•
•
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material!  
Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
•
Elektroden und dem Erdboden!  
Portuguese  
•
•
Não toque partes elétricas e electro-  
dos com a pele ou roupa molhada.  
Isole-se da peça e terra.  
•
Mantenha inflamáveis bem guarda-  
dos.  
•
Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE  
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE  
ESTE EQUIPOY LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU  
SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT  
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE  
EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-  
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS  
SIND EBENFALLS ZU BEACHTEN.  
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•
•
Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
•
•
Turn power off before servicing.  
•
•
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
•
•
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
•
•
Débranchez le courant avant l’entre-  
tien.  
•
•
N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
•
•
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öffnen;  
Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
•
•
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
•
•
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
•
•
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
•
•
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
•
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES  
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
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