Lincoln Electric LN-25X User manual

Operator’s Manual
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10532-A | Issue Date May-19
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12869, 12870, 12871, 12872
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
LN-25X
™

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.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
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

2
LN-25X™ TABLE OF CONTENTS
PAGE
GENERAL DESCRIPTION ..............................................................................................................................................7
RECOMMENDED PROCESSES ...............................................................................................................................7
PROCESS LIMITATIONS.........................................................................................................................................7
EQUIPMENT LIMITATIONS .....................................................................................................................................7
RECOMMENDED POWER SOURCES.......................................................................................................................7
OTHER POWER SOURCES......................................................................................................................................7
DESIGN FEATURES................................................................................................................................................7
INSTALLATION .........................................................................................................................................................A-1
TECHNICAL SPECIFICATIONS.............................................................................................................................A-1
SELECT SUITABLE LOCATIONS ..........................................................................................................................A-2
ACROSS THE ARC SET-UP WITH CROSSLINC™ COMMUNICATION (RECOMMENDED) ........................................A-3
ACROSS THE ARC SET-UPS WITHOUT CROSSLINC™ COMMUNICATION............................................................A-3
RECOMMENDED ELECTRODE AND WORK CABLE SIZES FOR ARC WELDING ......................................................A-5
COAXIAL WELD CABLE ......................................................................................................................................A-6
TRIGGER CONNECTOR.......................................................................................................................................A-7
CHANGING THE GUN RECEIVER BUSHING...........................................................................................................A-8
PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES................................................................................A-9
PRESSURE ARM ADJUSTMENT..........................................................................................................................A-9
GUN CONNECTION...........................................................................................................................................A-10
SHIELDING GAS CONNECTION .........................................................................................................................A-10
OPERATION ............................................................................................................................................................B-1
POWER-UP SEQUENCE......................................................................................................................................B-1
CASE FRONT CONTROLS...................................................................................................................................B-2
DIGITAL METER OPERATION..............................................................................................................................B-4
SET-UP MENU...................................................................................................................................................B-5
INTERNAL CONTROLS .......................................................................................................................................B-9
REAR CONTROLS ............................................................................................................................................B-11
OPTIONS/ACCESSORIES...........................................................................................................................................C.1
MAINTENANCE .........................................................................................................................................................D.1
ROUTINE MAINTENANCE....................................................................................................................................D.1
PERIODIC MAINTENANCE...................................................................................................................................D.1
TROUBLESHOOTING .................................................................................................................................................E-1
DIAGRAMS .............................................................................................................................................................F-1
Parts List.....................................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.
________________________________________________________________________

LN-25X™
General Description
The LN-25X™ is a rugged, portable, across-the-arc wire feeder
with CrossLinc™ and True Voltage Technology™ (TVT™). The
LN-25X is able to use 12” spools. The Extra Torque model
features additional torque gearing for reliable feeding of large
diameter FCAW wires. When used with a CrossLinc equipped
power source, this LN-25X allows the user to adjust the welding
voltage at the wire feeder front panel without the need for a
control cable. As a result, setup and changeover times reduced
while productivity is increased. TVT does the thinking so you don’t
have to. TVT learns. In as little as one weld, TVT begins to make
the necessary power source adjustments to ensure that the
voltage you set at the feeder will be the same voltage delivered to
the arc. TVT remembers. Set point adjustments remain – even
after the power to the LN-25X has been removed.
In addition to CrossLinc, the LN-25X wire feeder has the following
features:
• Wire drive geared for great performance with both FCAW and
GMAW wires up to 5/64” diameter.
• Plastic case molding from a high impact, flame retardant
material which is lightweight and extremely durable. The
patent pending design keeps the internal components
protected in harsh environments.
• MAXTRAC™ drive system. The patented features on the
MAXTRAC wire drive offer tool-less changing of the drive rolls
and wire guides for quick spool changes.
• Tachometer feedback on the wire drive ensures accurate
speed control with all wire types and environmental
conditions.
• Bright digital meters which display voltage, current, and wire
feed speed so that the user can accurately set and verify
welding parameters.
• Rating of 450 amps at a 60% duty cycle.
recoMMenDeD processes
• GMAW
• FCAW
process liMitations
• Not recommended for stitch or spot 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.
• Push-pull guns do not work with the LN-25X™.
• May not be converted to control cable operation.
recoMMenDeD poWer soUrces
• Flextec 350X™, Flextec 500X™, Flextec 650X™,
Ranger 330MPX
otHer poWer soUrces
• CV-250, 300, 305, 400, 655
• DC-400, 600, 655
• Invertec V-350, V-450
• Multi-Weld 350
• Ranger 10,000, 3 Phase, 225, 250, 250 GXT
• Ranger 250 LPG, 305
• Cross Country 300
• Vantage 300, 400, 500, 520, 600
• Air Vantage 500, 600, 650
• Dual Vantage 700
• Flextec 450, 500, 500P, 650
• Engine Drive Welder with a wire feed module
DesiGn FeatUres
Loaded with Standard Features Controls
• Digital displays with large voltage and wire feed speed knobs.
• Trigger interlock for comfort when making long welds.
• Cold-feed switch for wire feeding without activating welding
output
• Gas Purge switch for purging the gas path without activating
welding output.
3

A-1
INSTALLATIONLN-25X™
TECHNICAL SPECIFICATIONS -
INPUT - SINGLE PHASE
Input Voltage +/- 10%
Input Amperes @ Rated
Output
15 - 110V DC
4
MODEL SUMMARY
K# Description Meters Drive Roll Kit
Included Gun Bushing Installed Gun Bushing Shipped Loose
K4267-1 LN-25X™ DIGITAL ---- K1500-2 K1500-1
K4267-2 LN-25X™ W/O FLOW METER
(TWECO®)
K4267-3 LN-25X™ W/ FLOW METER
(TWECO®)
K4267-4 LN-25X™ CE
(TWIST MATE/DINSE)
K4267-5 LN-25X™ EXTRA TORQUE
(TWECO®)
RATED OUTPUT (ALL MODELS)
Duty Cycle Amperes
60% 450A
100% 325A
PHYSICAL DIMENSIONS
Model Height Width Depth Weight
K4267-1
K4267-2
K4267-3
K4267-4
K4267-5
14.8 in
(376 mm)
8.7 in
(221 mm)
23.2 in
(589 mm)
37 lbs
(17 kg)
TEMPERATURE RANGES
OPERATING TEMPERATURE
RANGE
STORAGE TEMPERATURE
RANGE
-14°F to 104°F (-10°C to 40°C) -40°F to 122°F (-40°C to 50°C)
Thermal tests have been performed at ambient temperature. The duty cycle
(duty factor) at 40°C has been determined by simulation.
GEARING - WIRE FEED SPEED RANGE-WIRE SIZE
WFS RANGE
50 – 400 ipm
(1.3 – 10.1m/min)
50 – 700 ipm
(1.3 – 17.7m/min)
WFS RANGE
50 – 400 ipm
(1.3 – 10.1m/min)
50 – 700 ipm
(1.3 – 17.7m/min)
WIRE SIZES
.023 – 1/16"
(0.6 – 1.6mm)
.023 – 1/16"
(0.6 – 1.6mm)
WIRE SIZES
.030 - 3/32”
(0.8 – 2.4mm)
.030 - 5/64
(0.8 - 2.0mm)
GEARING
Extra torque
K4267-5
Standard Speed
K4267-2
K4267-3
K4267-4
GMAW FCAW

A-2
INSTALLATIONLN-25X™
Read entire Installation Section before installing the
LN-25X™ .
INSTALLATION
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the
disconnect switch or fuse box before
attempting to connect or disconnect
input power lines, output cables or
control cables.
• Only qualified personnel should perform this
installation.
• Do not touch metal portions of the LN-25X™ 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.
SELECT SUITABLE LOCATION
For best wire feeding performance, place the LN-25X™ 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-25X™.
The LN-25X™ is rated IP23 and is suitable for outdoor use.
The handle of the LN-25X™ is intended for moving the wire
feeder about the work place only.
When suspending a wire feeder, insulate the hanging device from
the wire feeder enclosure.
High Frequency Interference Protection
Locate the LN-25X™ away from radio controlled machinery.
The normal operation of the LN-25X™ may adversely affect
the operation of RF controlled equipment, which may result
in bodily injury or damage to the equipment.
WARNING
CAUTION

across tHe arc set-Up WitH crosslinc™
(recoMMenDeD)
Place the power source Remote/Local switch in the Remote
position.
across tHe arc set-Ups WitHoUt crosslinc™
CV Power Sources with Stud Connectors with
Local/Remote Switch
Place the power source Remote/Local switch in the Local position.
+
_
A-3
INSTALLATIONLN-25X™
Item K# Description
1 K4267-2, K4267-3,
K4267-4, K4267-5
LN-25X™
2 KP1695-xx
KP1696-xx
KP1697-xx
Drive Roll Kit
3 See Magnum PRO
Literature
Welding Gun
4
-
Flextec 350X ™, 500X, 650X or
Ranger®330MPX
5 - Welding Cables
6 - Work Cable and Ground Clamp
Item K# Description
1
K4267-2, K4267-3,
K4267-4, K4267-5
LN-25X™
2 KP1695-xx
KP1696-xx
KP1697-xx
Drive Roll Kit
3 See Magnum PRO
Literature
Welding Gun
4
-
CV power source
5 - Electrode Cable
6
Work Cable and Ground Clamp
1
1
3
3
5
5
6
6
4
4
2
2CV-400
CV-600
DC-400
DC-600
DC-655
V450-PRO
SAE-400
w/ CV Adapter
Engine Drive Welder
w/ Wire Feed Module
Ranger 250 GXT
Vantage 520SD
Vantage 600
Air Vantage 600
Flextec 450
Flextec 500P

CV Power Sources with Stud Connectors and no
Remote/Local Switch
CV Power Source with Twist-Mate Connectors and
no Remote/Local Switch
+
_
A-4
INSTALLATIONLN-25X™
Item K# Description
1
K4267-2, K4267-3,
K4267-4, K4267-5
LN-25X™
2 KP1695-xx
KP1696-xx
KP1697-xx
Drive Roll Kit
3 See Magnum PRO
Literature
Welding Gun
4 CV power source
5 - Electrode Cable
6 - Work Cable and Ground Clamp
Item K# Description
1
K4267-2, K4267-3,
K4267-4, K4267-5
LN-25X™
2 KP1695-xx
KP1696-xx
KP1697-xx
Drive Roll Kit
3 See Magnum PRO
Literature
Welding Gun
4
-
CV power source
5 - Electrode Cables
6 - Work Cable and Ground Clamp
7 K484 Jumper Plug Kit* (14-Pin)
1
1
3
3
5
6
5
6
7
6
4
4
2
2
Ranger 250
Ranger 250 LPG
Ranger 305G
Ranger 305D
Ranger 10,000
Ranger 3 Phase
Ranger 225
Ranger 225 GXT
Commander 300
Vantage 300
Vantage 400
Vantage 500
Air Vantage 500
Air Vantage 650
SAE 300
Dual Vantage 700
Classic 300
*Not Shown

A-5
INSTALLATIONLN-25X™
recoMMenDeD electroDe anD WorK caBle
siZes For arc WelDinG
(See Table A.1)
Tabulated below are copper cable sizes recommended for
different currents and duty cycles. Lengths stipulated are the
distance from the welder to work and back to the welder again.
Cable sizes are increased for greater lengths primarily for the
purpose of minimizing cable drop.
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F OR 75°C)**
Amperes PERCENT
DUTY CYCLE
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES
0 to 50Ft.
(0 to15m)
50 to 100Ft.
(15 to 30m)
100 to 150 Ft.
(30 to 46m)
150 to 200 Ft.
(46 to 61m)
200 to 250 Ft.
(61 to 76m)
200 60 22211/0
200 100 2 2 21 1/0
225 20 4 or 5 34 or 5 1 1/0
225 40 & 30 3331 1/0
250 30 33311/0
250 40 22211/0
250 60 1 1 11 1/0
250 100 1111 1/0
300 60 1111/0 1/0
350 100 2/0 2/0 2/0 2/0 2/0
350 60 1/0 1/0 1/0 2/0 3/0
400 60 2/0 2/0 2/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
500 60 2/0 2/0 2/0 3/0 4/0
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables
larger than recommended, or cables rated higher than 167°F(75°C).
TABLE A.1

A-6
INSTALLATION
triGGer connector
There is one circular connector for the gun trigger on the front of
the LN-25X™
ELECTRIC SHOCK CAN KILL.
• Do not touch electrically live parts.
WARNING
LN-25X™
Picture Function Pin Wiring
5 PIN TRIGGER
CONNECTOR FOR
PUSH-ONLY GUNS.
A 15 VOLT SUPPLY
B NOT USED
C TRIGGER
D 83% WFS SWITCH
E 15 VOLT SUPPLY
A
E
CB
D

A-7
INSTALLATIONLN-25X™
cHanGinG tHe GUn aDapter BUsHinG
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding power source
before installation or changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger,
electrode and drive mechanism are
"hot" to work and ground and could
remain energized several seconds
after the gun trigger is released.
• Do not operate with covers, panels or guards removed
or open.
• Only qualified personnel should perform maintenance
work.
Tools required:
• ¼" hex key wrench
Note: Some gun adapters do not require the use
of the thumb screw.
1. Turn power off at the welding power source.
2. Remove the welding wire from the wire drive.
3. Remove the thumb screw from the wire drive.
4. Remove the welding gun from the wire drive.
5. Loosen the socket head cap screw that holds
the connector bar against the gun adapter.
Important: Do not attempt to completely
remove the socket head cap screw.
6. Remove the outer wire guide, and push the gun
adapter out of the wire drive. Because of the
precision fit, light tapping may be required to
remove the gun bushing.
7. Disconnect the shielding gas hose from the gun
bushing, if required.
8. Connect the shielding gas hose to the new gun
adapter, if required.
9. Rotate the gun adapter until the thumb screw
hole aligns with the thumb screw hole in the
feedplate. Slide the gun receiver bushing into
the wire drive and verify the thumb screw holes
are aligned.
10. Tighten the socket head cap screw.
11. Insert the welding gun into the gun adapter and
tighten the thumb screw.
WARNING
TIGHTEN
Gun Adapter
Thumb Screw
Outer Wire Guide
¼" Hex Key Wrench
LOOSEN
FIGURE A.2

A-8
INSTALLATIONLN-25X™
proceDUre to install Drive rolls anD
Wire GUiDes
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding power source
before installation or changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger,
electrode and drive mechanism are
"hot" to work and ground and could
remain energized several seconds
after the gun trigger is released.
• Do not operate with covers, panels or guards removed
or open.
• Only qualified personnel should perform maintenance
work.
1. Turn power off at the welding power source.
2. Release the idle roll pressure arm.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them from the
feedplate.
4. Rotate the triangular lock and remove the drive rolls.
5. Remove the inner wire guide.
6. Insert the new inner wire guide, groove side out, over the two
locating pins in the feedplate.
7. Install a drive roll on each hub assembly secure with the
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.
pressUre arM aDjUstMent
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding
power source before installation or
changing drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and drive
mechanism are "hot" to work and ground and could
remain energized several seconds after the gun trigger
is released.
• Do not operate with covers, panels or guards removed
or open.
• Only qualified personnel should perform maintenance
work.
The pressure arm controls the amount of force the drive rolls exert
on the wire. Proper adjustment of the pressure arm gives the best
welding performance.
Set the pressure arm as follows:
WARNING WARNING
FIGURE A.3
1
2
Aluminum
FCAW
GMAW
4
5
6
3
Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
UNLOCKED
POSITION
LOCKED
POSITION

A-9
INSTALLATIONLN-25X™
GUn connection
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the welding power source
before installation or changing drive
rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger,
electrode and drive mechanism are
"hot" to work and ground and could
remain energized several seconds after the gun trigger
is released.
• Do not operate with covers, panels or guards removed
or open.
• Only qualified personnel should perform maintenance
work.
The LN-25X™ comes with a K1500-2 gun adapter installed. 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.
Note: Not all gun bushings require the use of the thumb screw.
sHielDinG Gas connection
CYLINDER may explode if damaged.
• Keep cylinder upright and chained
to support.
• Keep cylinder away from areas
where it may be damaged.
• Never lift welder with cylinder
attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live electrical
circuits.
Build up of shielding gas may
harm health or kill.
• Shut off shielding gas supply when
not in use.
• See American National Standard
Z-49.1, "Safety in Welding and
Cutting” Published by the American Welding Society.
Maximum inlet pressure is 100 psi. (6.9 bar.)
Install the shielding gas supply as follows:
1. Secure the cylinder to prevent it from falling.
2. Remove the cylinder cap. Inspect the cylinder valves and
regulator for damaged threads, dirt, dust, oil or grease. Remove
dust and dirt with a clean cloth. DO NOT ATTACH THE
REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT!
Inform your gas supplier of this condition. Oil or grease in the
presence of high pressure oxygen is explosive.
3. Stand to one side away from the outlet and open the cylinder
valve for an instant. This blows away any dust or dirt which
may have accumulated in the valve outlet.
4. Attach the flow regulator to the cylinder valve and tighten the
union nut(s) securely with a wrench. Note: if connecting to
100% CO2cylinder, insert regulator adapter between regulator
and cylinder valve. If adapter is equipped with a plastic washer,
be sure it is seated for connection to the CO2cylinder.
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.
WARNING WARNING
Thumb Screw
Gun

B-1
OPERATION
OPERATION
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
ARC RAYS can burn.
• Wear eye, ear and body protection.
Observe additional Safety Guidelines detailed
in the beginning of this manual.
The serviceability of a product or structure utilizing the LN-25X™
wirefeeder is and must be the sole responsibility of the
builder/user. Many variables beyond the control of The Lincoln
Electric Company affect the results obtained in using the LN-
25X™ wirefeeder. These variables include, but are not limited to,
welding procedure, plate chemistry and temperature, weldment
design, fabrication methods and service requirements. The
available range of the LN-25X™ wirefeeder may not be suitable
for all applications, and the builder/user is and must be solely
responsible for welding settings.
poWer-Up seQUence
If the gun trigger is activated during power up, the feeder will not
operate until the gun trigger is released.
GrapHic sYMBols tHat appear on tHis
MacHine or in tHis ManUal
WARNING
LN-25X™
INPUT VOLTAGE
WARNING OR CAUTION
HIGH TEMPERATURE
READ INSTRUCTION
MANUAL
GAS INPUT
SINGLE PHASE
PROTECTIVE
GROUND
OUTPUT ON
GAS PURGE
A

B-2
OPERATION
case Front controls
Wire Feed Speed Digital Display
The LN-25X™ has a digital display that shows the wire feed
speed. This display is also capable of displaying amperage and
the setup menu.
Wire Feed Speed Knob
Use the Wire Feed Speed Knob to set the rate of wire feed speed.
The wire feed speed will be displayed on the Wire Feed Speed
Digital Display. During CV operation, the wire feed speed will
remain a constant value, independent of arc voltage changes, as
along as the arc voltage does not drop below the values per the
following table.
Voltage Digital Display
The LN-25X™ has a digital display that shows the voltage
between electrode and work. This display is also capable of
displaying the setup menu.
Voltage Knob
Use the Voltage Knob to set the voltage when connected to a
CrossLinc™ Power Source, otherwise the display will show
dashes. The voltage will be displayed on the Voltage Digital
Display. During CV operation, the voltage will remain stable while
welding.
83% Wire Feed Speed
The 83% wire feed speed reduces the wire feed speed to 83% of
the original set value when activated. For example, if the original
wfs = 200 in/min, the feeder will regulate to 0.83 x 200 = 166
in/min.
The 83% trigger requires a gun with a dual procedure switch.
This feature is often useful when welding pipe, and a “cooler”
procedure is required on the bottom portion.
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.
CV Operation
Minimum Arc
Volts
Maximum WFS
(Standard Torque)
Maximum WFS
(Extra Torque)
15 V 400 220
17 V 450 250
21 V 570 300
24 V 650 350
27 V 700 400
LN-25X™
13
9
12
4
8
7
5
2
10
11
Item Description
1 Wire Feed Speed Digital Display
2 Wire Feed Speed Knob
3 Voltage Digital Display
4 Voltage Knob
5 Thermal LED
6 CrossLinc™ LED
7 Wire Feed Speed LED
8 Amperage LED
9 Voltage LED
10 5 Pin Gun Trigger Connector
11 Work Sense Lead
12 True Voltage Technology (TVT)
6

B-3
OPERATION
True Voltage Technology (TVT)
When the TVT LED is illuminated, the CrossLinc™ enabled power
source is compensating for the voltage dropped across the
electrode in between the power source and LN-25X™.
CrossLinc™ LED
The CrossLinc™ LED displays whether the feeder is connected to
the power source. When the feeder has successfully connected to
the power source, the LED will illuminate.
Wire Feed Speed LED and Amperage LED
The Wire Feed Speed and Amperage LEDs will communicate what
is being displayed on the Wire Feed Speed Digital Display. When
the Wire Feed Speed LED is illuminated, wire feed speed is being
displayed. When the Amperage LED is illuminated, amperage is
being displayed.
Voltage LED
The Voltage LED will be illuminated when the Voltage Digital
Display is displaying actual voltage or when its displaying with a
CrossLinc™ connection.
Five Pin Gun Trigger Connector
The 5 Pin Gun Trigger Connector is where the trigger that is
attached to the welding gun is connected. This will actuate the
welding current when the trigger is pulled.
Work Sense Lead
The Work Sense Lead is used to power the feeder and
communicate with the power source. Connecting the Work Sense
Lead is critical for the operation of the feeder, as it will not power
up if it is disconnected.
LN-25X™

B-4
OPERATION
LN-25X™
DiGital Meter operation
CrossLinc™
When connected to a power source that supports CrossLinc™, the
CrossLinc™ LED will be illuminated when a connection is made
between the feeder and power source.
When connected to a power source that does not support
CrossLinc™, the CrossLinc™ LED will not be illuminated.
Idle
The left display shows the preset wire feed speed. The right
display shows the preset voltage when it is connected to a power
source that supports CrossLinc™ and CrossLinc communication
is activated.. It will display dashes when connected to a power
source that does not support CrossLinc™, meaning that voltage
can not be preset from the feeder and must be set at the power
source.
When connected to a power source with CrossLinc ™
When connected to a power source without CrossLinc ™
During Welding
The value in the left display will be either amps or actual wire feed
speed, depending upon the selection chosen in the set-up menu.
The corresponding LED below the display will light. Note that
actual WFS may not match preset WFS, if welding at low voltages
with high wire feed speeds. The right display shows the arc
voltage. If the wire feeder is connected for electrode negative
welding, then the voltage display shows a minus sign.
After Welding
The display continues to hold the value of the amperage or WFS
and arc voltage for ten seconds after welding stops. The
amperage or WFS and voltage displays flash. For 10 sec or until
the WFS or V knobs are rotated.
Wire Feed Speed Voltage Preset
200 180
.
Wire Feed Speed
200 ----
Actual Amperage
300 -257
Actual Voltage
.
CrossLinc™