Lincoln Electric Ln 8 Svm132 A Users Manual Svm132a

SVM132-A to the manual fc4a2110-b391-452e-97fe-4fe2779a7b57

2015-02-09

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SVM132-A
May, 2002

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LN-8 SEMIAUTOMATIC WIRE FEEDER
For use with code numbers: 9963, 9964

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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.

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SERVICE MANUAL

• 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 WEB SITE: www.lincolnelectric.com

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SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines

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.

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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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

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.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

____________________________________________________
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.

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:

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____________________________________________________

2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.

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.

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
possible to the area being welded.
2.d.5. Do not work next to welding power source.

Mar ‘95
LN-8

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ARC RAYS can burn.

ELECTRIC SHOCK can
kill.

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.

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:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.

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 with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

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.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.

3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

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SAFETY

3.g. Never dip the electrode in water for cooling.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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.d. 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.

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.

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5.e. Also see item 1.b.

LN-8

Mar ‘95

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iii

WELDING SPARKS can
cause fire or explosion.

CYLINDER may explode
if damaged.

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.

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.

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.

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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.

• 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.

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.

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iii

SAFETY

FOR ELECTRICALLY
powered 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 circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

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.

6.h. Also see item 1.c.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

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Mar ‘95

LN-8

iv
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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.
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.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
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.

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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 suivantes:

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SAFETY

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

PRÉCAUTIONS DE SÛRETÉ

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:

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 levage, 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.
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.
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.
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
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
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.

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.
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,
pantalons sans revers, et chaussures montantes.

3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93
LN-8

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i-iv

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - LN-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
Power Source Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-5
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-18
LN-8S and LN-8SE Continuous Flux Feed (Submerged Arc) . . . . . . . . . .
A-18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-4
Avoiding Ground Lead Protector (GLP) Activation . . . . . . . . . . . . . . . . . .
B-4
Wire Feed Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-5
Setting for CV or CC Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Welding with a Constant Voltage Power Source . . . . . . . . . . . . . . . . . . . .
B-7
Welding with a Constant Current Power Source . . . . . . . . . . . . . . . . . . . .
B-7
Wire Reel Loading - 50 and 60 lb. Coils (K303 Wire Reel Stand) . . . . . . .
B-8
Wire Reel Loading (K1524-1 Unversal Wire Reel Stand) . . . . . . . . . . . . . .
B-9
Slow Acceleration Starting (Code 7926 and Above) . . . . . . . . . . . . . . . . .
B-12
Flux Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-12
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-2
Reel Mounting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-4
Welding Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-5
Welding Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-5
Constant Current Conversion Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-2
Power Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-2
Gun Trigger and 1CR Relay Contact Control Circuits . . . . . . . . . . . . . . . .
E-3
Variable Voltage Board, Meter Shunt, Wire Speed
and Remote Output Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-4
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-5
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-4
LN-8 Electrical Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-10
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-12
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-24
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-40
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P293 Series
LN-8

INSTALLATION

SECTION A-1

TABLE OF CONTENTS
-INSTALLATION SECTIONInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications - LN-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
Power Source Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
LN-8N and LN-8NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
LN-8S and LN-8SE (and converted LN-8N and LN-8NE) . . . . . . . . . . . . . . . . . . . . . .
A-4
Power Source Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-5
Connection of the LN-8 to an Idealarc R3S-400, 600 or 800
(with LVC) (Discontinued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6
Connection of LN-8 to an Idealarc R3S-400, 600 or 800
(without LVC) (Discontinued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-7
Connection of LN-8 to a Sam Motor-Generator or Engine Driven Welder. . . . . . . . . .
A-8
Connection of LN-8 to R3S-250 and R3S-325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-9
Connection of LN-8 to DC-600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-10
Connection of LN-8 to DC-250, 400 and CV/CVI Power Sources . . . . . . . . . . . . . . . .
A-11
K318 Dual Process Contactor Kit DC-400, CV-400 and CVI-500 Connection
to LN-8 for Same Polarity Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-12
K318 Dual Process Contactor Kit DC-400, CV-400 and CVI-500 Connection
to LN-8 for Opposite Polarity Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-13
For Power Sources Other Than Lincoln Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-14
Input Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-15
LN-8N and LN-8S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-15
LN-8NE and LN-8SE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-15
Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-18
Gun Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-18
Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-18
LN-8S and LN-8SE Continuous Flux Feed (Submerged Arc) . . . . . . . . . . . . . . . . . . . . . .
A-18

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SECTION A-1

LN-8

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A-2

TECHNICAL SPECIFICATIONS – LN-8
INPUT – VOLTAGE
115 VAC, 50/60 Hz @ 4.5 amps
WIRE FEED SPEED
50 in. to 600 in. per minute (1.25 to 15.24 m/min)
WIRE DIAMETERS
ELECTRODE

DIAMETER

SOLID

0.030 in. through 3/32 in. (0.76 through 2.36 mm)

CORED

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OPERATING
STORAGE

LN-8 WITH K303
(50-60 lb wire reel stand
with dust cover over reel)
LN-8 WITH K377
(small stand equipped for
Readi-Reel)
LN-8 WITH K378
(small stand equipped for
14 lb Innershield coil)

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*
**
***
(◊)

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A-2

INSTALLATION

0.062 in. through 0.120 in. (1.57 through 3.05 mm)
TEMPERATURE RATING
-4˚F to 104˚F (-20˚C to 40˚C)
-31˚F to 185˚F (-35˚C to 85˚C)
PHYSICAL DIMENSIONS

LENGTH
30.25 in.
(768 mm)
*
22.19 in.
(564 mm)

WIDTH
9.75 in.
(248 mm)
**
9.44 in.
(240 mm)

HEIGHT
26.50 in.
(673 mm)

WEIGHT WIRE
DRIVE UNIT ONLY
36.0 lb (◊)
(16.3 kg)

17.00 in.
(432 mm)

36.0 lb
(16.3 kg)

TOTAL WEIGHT
LESS ELECTRODE
80.0 lb. (◊)
(36.3 kg)
***
48.0 lb.
(21.8 kg)

25.68 in.
(652 mm)

9.44 in.
(240 mm)

17.00 in.
(432 mm)

36.0 lb
(16.3 kg)

48.0 lb.
(21.8 kg)

Add 1.00 in. (25.4 mm) to length if door kit is attached.
Add 0.50 in. (12.7 mm) to width if door kit is attached.
Add 7.31 lbs (3.32 kg) to total weight if door kit is attached.
Codes below 7926-33.5 lbs (15.2 kg) and 78.5 lbs (35.6 kg)

LN-8

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A-3

MOUNTING LOCATION

LN-8N AND LN-8NE

The LN-8 can be operated as a free-standing unit, or it
can be mounted to an undercarriage when portability
is required. Refer to Accessories Section for available under carriage, mounting platform, or wire reel
stands.

Use a constant voltage type power source. If the LN-8
has been converted to weld with a constant current
power source, use the instructions for the LN-8S.

POWER SOURCE CONNECTIONS
Use the type of power source required for the specific
welding application.

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CAUTION
Never operate a Lincoln Squirt welder wire feeder with
a power source that has a jumper from #2 to #4 on the
terminal strip, or with a power source without a
contactor. To do so would defeat the ground lead
protector circuit and could result in overheating of the
electrical ground circuit to the wire feeder.

____________________________________
A constant voltage power source is required for
Innershield electrode and other open arc welding. It is
often preferred for small, single pass submerged arc
welds at fast travel speeds.
Formerly, a constant current power source was recommended for most submerged arc welding. With the
innovation of the new DC power sources, a special
mode (CV Sub-Arc) is available and is preferred for
most submerged arc welding.
The LN-8N and LN-8NE, when shipped, can only be
used with a constant voltage power source. These
models can be converted to weld with a constant current power source with the installation of the proper
conversion parts.
The LN-8S and LN-8SE, when shipped, can weld with
either a constant voltage or constant current power
source. Be sure that both the power source and the
wire feeder are properly set for the required procedure.

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Refer to the “Input Cable Connections” section
when connecting the LN-8 to a Lincoln power source.
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A-3

INSTALLATION

LN-8

1. If using a multi-purpose power source, be sure it
is set for constant voltage welding per the
instructions in the power source operating
manual.
2. Connect the LN-8 input cable to the power source
exactly as specified on the appropriate
connection diagram, see Table A.2. Include any
jumpers on the terminal strips as shown in the
applicable diagram.
3. Connect a work lead of sufficient size and length
per Table A.1, between the appropriate output
terminal on the power source and the work.
Ensure the connection to the work makes tight
metal-to-metal contact.

TABLE A.1 – WORK LEAD SPECIFICATIONS
Copper Work Cable Length
Current Amps
60% Duty
Cycle

25 ft
(7.5 m)

50 ft
(15 m)

100 ft
(45 m)

300

000

400

0000

500

000

0000

600

000

Two 000

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A-4

FIGURE A.1 – POWER SOURCE SELECTION
SWITCH

LN-8S AND LN-8SE (AND CONVERTED
LN-8N AND LN-8NE)
1. Use either a constant voltage or constant current
type power source as required for the application.
Ensure the power source is properly set for
constant voltage or constant current welding, as
appropriate, per the instructions in the power
source operating manual.

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2. Set the LN-8 wire feeder for a constant voltage or
constant current power source as appropriate per
the following:

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A-4

INSTALLATION

POWER SOURCE
SELECTION SWITCH

VARIABLE
VOLTAGE
PC BOARD

a. There are two nameplates on the front of the
wire feeder, one mounted on top of the other.
Be sure the ‘Constant Current Power Source’
nameplate is on top when using a constant
current power source. When connected to a
constant voltage power source, be sure the
‘Constant Voltage Power Source’ nameplate is
on top.
b. Turn the power to the wire feeder off. Open the
door to the control section and switch the
power source selection switch to constant
current ‘CC’ or constant voltage ‘CV’ as
appropriate. See Figure A.1.
3. Connect the LN-8 input cable to the power source
exactly as specified in the wire connection
diagrams in Table A.2. Include any jumpers on
the terminal strips as shown in the connection
diagrams.
4. Connect a work lead of sufficient size and length,
per Table A.1, between the appropriate output
terminal on the power source and the work.
Ensure the connection to the work makes tight
metal-to-metal contact.

LN-8

VARIABLE
VOLTAGE
PC BOARD

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A-5

INSTALLATION

POWER SOURCE CONNECTION DIAGRAMS
Table A.2 – LN-8 Power Source Connection Diagrams
Figure No.

Power Source

A.2

Connection of LN-8 to an Idealarc® R3S-400, 600 or 800 (with LVC) (Discontinued)

A.3

Connection of LN-8 to an Idealarc R3S-400, 600 or 800 (without LVC) (Discontinued)

A.4

Connection of LN-8 to a SAM Motor-Generator or Engine Driven Welder

A.5

Connection of LN-8 to R3S-250 and R3S-325

A.6

Connection of LN-8 to DC-600

A.7

Connection of LN-8 to DC-250, 400 and CV/CVI Power Sources

A.8

K318 Duel Process Contactor Kit
DC-400, CV-400, and CVI-500 Connection to LN-8 for Same Polarity Operation

A.9

K318 Duel Process Contactor Kit
DC-400, CV-400, and CVI-500 Connection to LN-8 for Opposite Polarity Operation

A.10

Power Sources other than Lincoln Electric

LN-8

A-5

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A-6

INSTALLATION
FIGURE A.2 – CONNECTION OF LN-8 TO AN IDEALARC R3S-400, 600 OR 800
(WITH LVC) (DISCONTINUED)

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

TO OPTIONAL R3S
LINE VOLTAGE
COMPENSATOR

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N.A.
TO LN-8
INPUT CABLE PLUG
21

A
B
C
4
GND
32
31
2
21

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NEGATIVE

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N.D.

POSITIVE

LN-8 CONTROL
CABLE

N.B.
ELECTRODE CABLE TO
WIRE FEED UNIT

N.C.
N.B.

TO WORK
POWER SOURCE
TAPE UP BOLTED CONNECTION

THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY. TO CHANGE POLARITY, TURN OFF THE POWER,
REVERSE THE ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE "CONTROL SWITCH" AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. ON EARLIER R3S-400, -600, AND -800 MACHINES, TERMINALS #67 AND #1 WERE ALSO ON THE TERMINAL STRIP.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD
#21 SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.D. LN-8 LEADS A, B, AND C (#75, #76, AND #77 ON OLDER LN-8 CONTROL CABLES) ARE TAPED UP WHEN THE R3S LINE VOLTAGE
COMPENSATOR IS CONNECTED. ARC VOLTAGE IS CONTROLLED BY THE LINE VOLTAGE COMPENSATOR RHEOSTAT. THERE WILL BE NO
ADJUSTMENTS OF VOLTAGE BY THE LN-8 VOLTAGE CONTROL.

CLEVELAND, OHIO U.S.A.

LN-8

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A-7

INSTALLATION
FIGURE A.3 – CONNECTION OF LN-8 TO AN IDEALARC R3S-400, 600 OR 800
(WITHOUT LVC) (DISCONTINUED)

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

N.E.

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N.A.
TO LN-8
INPUT CABLE PLUG
21

C
B
A
4
GND
32
31
2
21

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NEGATIVE

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N.D.

POSITIVE

LN-8 CONTROL
CABLE

N.B.
ELECTRODE CABLE TO
WIRE FEED UNIT

N.C.
N.B.

TO WORK
POWER SOURCE
TAPE UP BOLTED CONNECTION

THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY. TO CHANGE POLARITY, TURN OFF THE POWER,
REVERSE THE ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE "CONTROL SWITCH" AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. ON EARLIER R3S-400, -600, AND -800 MACHINES, TERMINALS #67 AND #1 WERE ALSO ON THE TERMINAL STRIP.
N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.C. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD
#21 SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.D. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON THE TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON THE TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.
N.E. UPPER TERMINAL STRIP (#75, #76 AND #77) MAY NOT APPEAR ON OLDER R3S MACHINES. LEADS A, B, AND C SHOULD BE TAPED UP.
THERE WILL BE NO ADJUSTMENT OF VOLTAGE BY THE LN-8 VOLTAGE CONTROL.

CLEVELAND, OHIO U.S.A.

LN-8

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A-8

INSTALLATION

FIGURE A.4 – CONNECTION OF LN-8 TO A SAM MOTOR-GENERATOR OR ENGINE DRIVEN WELDER

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

TAPE UP
BOLTED
N.A. CONNECTION

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REMOVE SAM PORTABLE FIELD CONTROL AND
CONNECT LEADS B AND C FROM LN-8 CONTROL CABLE.
DO NOT CONNECT LEAD A. LEAD MUST BE TAPED UP.

TO LN-8 INPUT
CABLE PLUG

21
67
1
2
31
32
C4

21
2
31
32
4
GND
C
B

77
76
75
AUTO
EQUIP.

STICK

CONTROL CABLE

ELECTRODE CABLE TO
WIRE FEED UNIT
N.B.

WORK

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TAPE
UP

POWER
SOURCE

TO WORK

CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK).
N.B. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #76 TO #76 ON TERMINAL
STRIP, CONNECT LEAD #77 TO #75 ON THE TERMINAL STRIP, AND TAPE UP LEAD #75.

CLEVELAND, OHIO U.S.A.

LN-8

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A-9

INSTALLATION
FIGURE A.5 – CONNECTION OF LN-8 TO R3S-250 AND R3S-325

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

TAPE UP
BOLTED
CONNECTION

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POWER SOURCE

NEGATIVE

N.B.

TO LN-8 INPUT
CABLE PLUG

21
4
31
32

21
4
31
32
2
GND

77
76
75

C
B

CONTROL CABLE

N.C.

POSITIVE

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ELECTRODE CABLE TO LN-8 OR
NA-3 AUTOMATIC SHUNT
N.A.
TO WORK

THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED FOR POSITIVE POLARITY. TO CHANGE POLARITY, TURN OFF THE POWER,
REVERSE THE ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND REVERSE THE 'CONTROL SWITCH' AT THE POWER
SOURCE.
CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL STRIP
OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACKET.)
N.C. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING), CONNECT LEAD #75 TO #75 ON THE TERMINAL
STRIP, LEAD #76 TO #76 ON THE TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.

CLEVELAND, OHIO U.S.A.

LN-8

A-10

INSTALLATION
FIGURE A.6 – CONNECTION OF LN-8 TO DC-600

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A-10

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

POWER SOURCE

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NEGATIVE

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TO LN-8 INPUT
CABLE PLUG

N.E.

CONTROL
CABLE

GND
N

N.F.

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C
B
A
32
31
2
4
21

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N.D.

N.B. AND N.C.

POSITIVE

ELECTRODE CABLE TO
WIRE FEED UNIT
N.A.
TO WORK
THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN OFF THE POWER, REVERSE THE
ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND POSITION THE SWITCH ON THE POWER SOURCE TO PROPER
POLARITY.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ] REMOTE
VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (THIS EXTENDED #21 LEAD CONNECTION REPLACES THE NEED TO EMPLOY THE
REMOTE WORK LEAD ACCESSORY ON LN-8 METER KITS WHICH HAVE A DIRECT WORK LEAD JACK.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL
STRIP OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.E. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON TERMINAL STRIP.
N.F. FOR DC-600 CODES BELOW 8200, CONNECT A JUMPER FROM 'N' TO 'S' ON LN-8 ONLY. THERE IS NO NPS TERMINAL STRIP ON CODES
ABOVE 8200.

CLEVELAND, OHIO U.S.A.

LN-8

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A-11

INSTALLATION
FIGURE A.7 – CONNECTION OF LN-8 TO DC-250, 400 AND CV/CVI POWER SOURCES

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

POWER SOURCE

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TO LN-8 INPUT
CABLE PLUG

C
B
A
32
31
2
4
GND

CV OUTPUT
TERMINALS ON
DC-250
NEGATIVE

N.E.

CONTROL CABLE

21
POSITIVE
N.D.
N.B. AND N.C.
ELECTRODE CABLE TO
WIRE FEED UNIT

N.A.

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TO WORK

THE ABOVE DIAGRAM SHOWS THE ELECTRODE CONNECTED POSITIVE. TO CHANGE POLARITY, TURN OFF THE POWER, REVERSE THE
ELECTRODE AND "TO WORK" LEADS AT THE POWER SOURCE, AND POSITION THE SWITCH ON THE POWER SOURCE AND WIRE FEEDER
(IF EQUIPPED) TO PROPER POLARITY. ALSO REFER TO THE FOLLOWING NOTE:
NOTE: IF LEAD #21 IS TO BE CONNECTED TO THE TERMINAL STRIP, CONNECT TO TERMINAL #21 THAT MATCHES WORK POLARITY. THIS
CONNECTION MUST BE CHANGED WHENEVER THE ELECTRODE POLARITY IS CHANGED. THIS DOES NOT APPLY TO DC-400 BELOW
CODE 9200 WITH POLARITY SWITCH.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. EXTEND LEAD #21 USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[ ]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THIS EXTENDED LEAD #21
SHOULD BE TAPED TO THE WELDING WORK LEAD. (IF THE LENGTH OF THE WORK LEAD CIRCUIT IS SHORT, AND CONNECTIONS CAN BE
EXPECTED TO BE RELIABLE, THEN CONTROL CABLE LEAD #21 DOES NOT NEED TO BE EXTENDED AND CAN BE DIRECTLY CONNECTED
TO TERMINAL #21 ON THE TERMINAL STRIP. NOTE THAT THIS IS NOT THE PREFERRED CONNECTION BECAUSE IT ADDS ERROR TO THE
WIRE FEEDER VOLTMETER READING.)
N.C. TAPE UP BOLTED CONNECTION.
N.D. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL
STRIP. THE POWER SOURCE GROUNDING TERMINAL STRIP (MARKED
AND LOCATED NEAR THE POWER SOURCE INPUT POWER
CONNECTIONS) MUST BE PROPERLY CONNECTED TO ELECTRICAL GROUND PER THE POWER SOURCE OPERATING MANUAL.
N.E. IF USING AN OLDER LN-8 CONTROL CABLE (PRIOR TO USE OF A, B, AND C MARKING): CONNECT LEAD #75 TO #75 ON TERMINAL
STRIP, CONNECT LEAD #76 TO #76 ON TERMINAL STRIP, AND CONNECT LEAD #77 TO #77 ON THE TERMINAL STRIP.

CLEVELAND, OHIO U.S.A.

LN-8

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A-12

FIGURE A.8 – K318 DUAL PROCESS CONTACTOR KIT DC-400, CV-400 AND CVI-500 CONNECTION TO
LN-8 FOR SAME POLARITY OPERATION

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

N.B.B.

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21A

21B

WELDING LEAD STUD ON
BACK OF CONTACTOR KIT
GND

GND

N.C.
21

80
77
76
75
4
GND
2
31
32

N.A.A.

TO NEGATIVE OUTPUT
STUD ON POWER
SOURCE

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DUAL PROCESS
CONTACTOR

DC-400

N.F.

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A-12

INSTALLATION

B
75
76
77

A
B
C

4
2
32
31

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B
N.B.

N.B.

WELDER
CONTROL
CABLE

4
2
32
31

A
TO POSITIVE OUTPUT
STUD ON POWER
SOURCE

A
B
C

N.E.

N.D.
N.A.

WIRE FEEDER ELECTRODE WIRE FEEDER
CABLES
CONTROL
CONTROL
CABLE
CABLE

TO WORK

N.A.
TO "A" WIRE FEEDER

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75
76
77

N.A.
TO "B" WIRE FEEDER

FOR 50 HZ OPERATION, DISCONNECT BOTH BROWN LEADS FROM TERMINAL 31B AND TAPE UP EACH LEAD. UNTAPE BOTH RED LEADS AND
CONNECT TO 31B.
N.A.A. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME TERMINAL MARKED
NEAR THE POWER SOURCE TERMINAL
STRIP OR TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.B.B. EXTEND LEAD #21A & #21B USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THESE EXTENDED #21A AND #21B
LEADS SHOULD BE TAPED TO THE WELDING WORK LEAD. EACH LEAD MUST BE CONNECTED DIRECTLY TO THE WORK AND LEADS MUST
NOT BE CONNECTED TOGETHER.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. BOLT AND TAPE CONNECTIONS.
N.C. TAPE UP SEPARATELY.
N.D. PUT TRANSFER SWITCH IN "SAME POLARITY ON FEEDERS" POSITION.
N.E. MODE SWITCHES ON CONTACTOR KIT ARE NOT FUNCTIONAL WHEN USED WITH THE POWER SOURCE.
N.F. CONNECTION SHOWN FOR NEGATIVE POLARITY. FOR POSITIVE POLARITY REVERSE ELECTRODE AND WORK CABLES CONNECTED TO
POWER SOURCE OUTPUT STUDS.
CLEVELAND, OHIO U.S.A.

LN-8

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A-13

INSTALLATION

FIGURE A.9 – K318 DUAL PROCESS CONTACTOR KIT DC-400, CV-400 AND CVI-500 CONNECTION TO
LN-8 FOR OPPOSITE POLARITY OPERATION

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

N.B.B.

N.B.B.
21A

TO WORK

N.A.

21B

DUAL PROCESS
CONTACTOR

WELDING LEAD STUD ON
BACK OF CONTACTOR KIT

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DC-400
GND
21

80
77
76
75
4
GND
2
31
32

N.A.A.

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TO NEGATIVE OUTPUT
STUD ON POWER
SOURCE

B
75
76
77

A
B
C

75
76
77

A
B
C

4
2
32
31

N.F.

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GND

N.C.

4
2
32
31

B
N.B.

N.B.

TO POSITIVE OUTPUT
STUD ON POWER
SOURCE
WELDER
CONTROL
CABLE

N.E.

N.D.
WIRE FEEDER ELECTRODE WIRE FEEDER
CABLES
CONTROL
CONTROL
CABLE
CABLE

N.A.

N.A.
TO "A" WIRE FEEDER
ELECTRODE NEGATIVE

N.A.
TO "B" WIRE FEEDER
ELECTRODE POSITIVE

FOR 50 HZ OPERATION, DISCONNECT BOTH BROWN LEADS FROM TERMINAL 31B AND TAPE UP EACH LEAD. UNTAPE BOTH RED LEADS
AND CONNECT TO 31B.
N.A.A. CONNECT THE LN-8 CONTROL CABLE GROUND LEAD TO THE FRAME MARKED
NEAR THE POWER SOURCE TERMINAL STRIP OR
TO AN UNPAINTED FRAME SCREW. THE POWER SOURCE MUST BE PROPERLY GROUNDED.
N.B.B. EXTEND LEAD #21A AND #21B USING #14 OR LARGER INSULATED WIRE PHYSICALLY SUITABLE FOR THE INSTALLATION. AN S16586-[]
REMOTE VOLTAGE SENSING WORK LEAD IS AVAILABLE FOR THIS PURPOSE. CONNECT IT DIRECTLY TO THE WORK PIECE, KEEPING IT
ELECTRICALLY SEPARATE FROM THE WELDING WORK LEAD CIRCUIT AND CONNECTION. FOR CONVENIENCE, THESE EXTENDED #21A AND
#21B LEADS SHOULD BE TAPED TO THE WELDING WORK LEAD. EACH LEAD MUST BE CONNECTED DIRECTLY TO THE WORK AND LEADS
MUST NOT BE CONNECTED TOGETHER.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.
N.B. BOLT AND TAPE CONNECTIONS.
N.C. TAPE UP SEPARATELY.
N.D. PUT TRANSFER SWITCH IN "OPPOSITE POLARITY ON FEEDERS" POSITION.
N.E. MODE SWITCHES ON CONTACTOR KIT ARE NOT FUNCTIONAL WHEN USED WITH THE POWER SOURCE.
N.F. TO MAKE "A" FEEDER POSITIVE POLARITY AND "B" FEEDER NEGATIVE POLARITY, REVERSE ELECTRODE CABLES CONNECTED TO
POWER SOURCE OUTPUT STUDS.

CLEVELAND, OHIO U.S.A.

LN-8

A-14

INSTALLATION
FIGURE A.10 – FOR POWER SOURCES OTHER THAN LINCOLN ELECTRIC

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A-14

WARNING

ELECTRIC
SHOCK
CAN KILL

TURN OFF INPUT POWER
TO THE WELDING POWER
SOURCE USING THE
DISCONNECT SWITCH
BEFORE WORKING
ON THIS EQUIPMENT.

POWER SOURCE

INTERNALLY POWERED CONTACTOR
OUTPUT CONTACTOR COIL

EXTERNALLY POWERED CONTACTOR
OUTPUT CONTACTOR COIL
(115 VAC)
ELECTRODE

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ELECTRODE
FOR POWER TO
OPERATE CONTACTOR

MAX. RATING OF LN-8
#2 TO #4 CIRCUIT IS
5 AMP 115 VAC
5 AMP 28 VDC
1/2 AMP 115 VDC

WORK

MAX. RATING OR LN-8
#2 TO #4 CIRCUIT IS
5 AMP 115 VAC OR
5 AMP 28 VDC
1/2 AMP 115 VDC

GND
21

TO 115 VAC 350 VOLT-AMP
FOR LN-8 PLUS
CONTACTOR
REQUIREMENTS

2
TO 115 VAC 350
VOLT-AMP CAPACITY
TAPE UP
EACH LEAD

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TO LN-8 CIRCUIT

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WORK

31
32
75
76
77

TAPE UP
EACH LEAD

TO
WORK

INPUT
CONTROL
CABLE

TO LN-8 CIRCUIT

LN-8 WIRE FEEDER

ELECTRODE CABLE

4
2
31
32
75
76
77
INPUT
CONTROL
CABLE

LN-8 WIRE FEEDER

REFER TO THE POWER SOURCE WIRING DIAGRAM TO FIND THE TYPE OF CONTACTOR CIRCUIT.

CLEVELAND, OHIO U.S.A.

LN-8

TO
WORK

ELECTRODE CABLE

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A-15

INSTALLATION

2. Remove the screws holding the cable clamp
located near the rear of the wire reel base. Put
the control cable and electrode cable under the
clamp and install the screws. On cables with
more than one electrode cable, leave the junction
between the two or more cables and the single
4/0 stub behind the clamp so only the single
electrode lead is under the clamp.

INPUT CABLE CONNECTIONS
For connecting an LN-8 to a specific Lincoln Electric
power source, use the appropriate steps in one of
these paragraphs and refer to the connection diagrams listed on Table A.2 for the applicable power
source. Table A.2 lists each figure number with its
corresponding power source.

3. Pass the single electrode cable through the holes
provided in the back corner of the control section
and fasten it to the tab on the conductor above
the rear brass block of the wire feeder.

LN-8N AND LN-8S

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The input cable consists of an electrode cable and a
multi-conductor control cable. The control cable has a
polarized plug on the wire feeder end. To connect the
cables, refer to Figure A.11 and perform these steps:
1. Connect the polarized plug of the control cable to
the mating connector on the back of the wire
feeder.

FIGURE A.11 – INPUT CONTROL CABLE AND
ELECTRODE CABLE CONNECTIONS

A-15

LN-8NE AND LN-8SE
The extension unit consists of a wire reel mount with
a hand crank and either a 22-1/2 or 45 ft (6.9 or
13.7 m) extension cable assembly. The cable is rated
at 450 amps, 50% duty cycle. For higher currents
install a parallel length of 1/0 cable per step 10. The
extension cable can be used for 0.068 through
0.120 in. (1.7 through 3.0 mm) flux-cored electrode
and 5/64 through 3/32 in. (2.0 through 2.4 mm) solid
electrode. The 22-1/2 ft. (6.9 m) cables can also be
used for 1/16 in. (1.6 mm) solid electrodes. To connect the cables, perform these steps:

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1. When shipped, the hand crank on the wire reel
mount is equipped to feed 1/16 through 0.120 in.
(1.6 through 3.0 mm) electrode.

CABLE
CLAMP

CONDUCTOR
ELECTRODE
CABLE
WIRE
REEL
BASE

CONTROL
CABLE
LN-8

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A-16

INSTALLATION
FIGURE A.12 – INPUT CONTROL CABLE AND ELECTRODE CABLE EXTENSIONS
WIRE
DRIVE
UNIT

CONTROL
CABLE
EXTENSION

POLARIZED
PLUGS

CONTROL
CABLE

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ELECTRODE
CABLE
ELECTRODE
EXTENSION
CABLE

BRASS
BLOCK

2. The standard cable setup consists of an electrode
cable and a control cable with a polarized plug on
the wire feeder end. Position the control cable
with the polarized plug at the wire reel base. Refer
to Figure A.12.

HAND
CRANK

WIRE
REEL
BASE

FIGURE A.13 – CABLE EXTENSION
CONNECTIONS TO WIRE FEEDER

3. Connect the electrode cable to the brass block on
the hand crank assembly using the screw
provided.

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4. Position the 22-1/2 or 45 ft (6.9 or 13.7 m) control
cable extension so the polarized connector with
the threads on its O.D. is at the wire reel base.
5. Connect the polarized connectors of the control
cable together.

CONTROL
CABLE
EXTENSION

6. Place both the control and electrode cables under
the clamp on the wire reel base and tighten the
screws.
7. Insert the connector on the electrode cable
extension into the brass block of the hand crank
assembly and tighten with a 3/16 in. Allen wrench.

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8. At the wire feeder, connect the polarized plug of
the control cable extension into the mating
receptacle on the back of the wire feeder. Refer to
Figure A.13.
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LOCKING
SCREW

LN-8

REAR
BRASS
BLOCK
ELECTRODE
CABLE
EXTENSION
CONNECTOR

INGOING
GUIDE
TUBE

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A-17

9. Remove the ingoing guide tube from the rear
brass block of the wire feeder and plug the
connector of the electrode cable extension into
the brass block. Tighten the locking screw with a
3/16 in. Allen wrench. The guide tube is not used
when the extension assembly is installed.
10. If using over 450 amperes, connect a length of
1/0 cable between the brass block on the wire reel
base and the tab on the rear brass block of the
wire feeder. Tape this cable to the extension
assembly. Proper cable lengths are:

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• For a 22-1/2 ft (6.9 m) extension use 23-1/2 ft
(7.2 m) - order M5906-106

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A-17

INSTALLATION

conductor cable is 22-1/2 ft (6.9 m) long, tip to tip,
and can be used to measure the length of hose
cut off.) If the flux hose is taped to the extension
cables or gun cable, it should be done in such a
manner as not to deform or collapse the hose.

FIGURE A.14 – WIRE FEEDER HANDLE
INSTALLATION
SELF-TAPPING
SCREW
HINGE
PIN

• For 45 ft (13.7 m) extension use 46 ft (14 m) order M5906-104
11. To mount the wire feeder handle provided with
the extension unit, remove the two self-tapping
screws that hold the hinge pin in the top of the
wire feeder. Push the hinge pin out, leaving the
covers intact. Place the handles into the slots
provided and push the hinge pin back into the
assembly making sure that the pin goes through
the holes in the handle. Put the two self-tapping
screws back into their respective positions. Refer
to Figure A.14.
12. If the extension is being used with a K306 Wire
Reel Flux Tank assembly, the hose attached to
the bottom of the flux tank may have to be
shortened. This hose is 64 ft (19.5 m) long, and is
the correct length for use with the 45 ft (13.7 m)
extension. If a 22-1/2 ft (6.9 m) extension is to be
used, cut 22-1/2 ft (6.9 m) off the flux hose to give
the correct length of 41-1/2 ft (12.6 m). (The

LN-8

HANDLE

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A-18

INSTALLATION

GUN AND CABLE ASSEMBLIES

LN-8S AND LN-8SE CONTINUOUS
FLUX FEED (SUBMERGED ARC)

GENERAL
The LN-8 is used with various guns. In all cases, the
gun is shipped connected to the cable and is ready to
weld. Use the gun recommended for the wire type
(solid or cored) and size to be used. See the paragraph on Welding Guns in the Accessories Section
for more information on the different types of guns.

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GUN CABLE CONNECTIONS
Lay the cable out straight. Insert the male end of the
welding conductor cable into the brass block on the
front of the LN-8. Make sure it is in all the way and
tighten the locking screw with a 3/16 in. Allen wrench.
Keep this connection clean and bright. Connect the
control cable polarized plug into the receptacle next to
the coupling.

HANDLING PROCEDURES
1. Do not kink or pull the cable around sharp
corners.

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2. Keep the electrode cable as straight as practical
when welding or starting the electrode through
the cable.
3. Do not allow dolly wheels or trucks to run over the
cables.
4. Keep the cable clean
maintenance instructions.

following

the

Connect the loose end of the hose to the tube at the
back end of the welding gun. Tighten the hose clamp.
If the hose is taped to the gun cable, be sure it is not
collapsed or deformed as this could cause flux feeding problems.
The air for the automatic flux feeding system is
obtained from the regular plant compressed air system, providing the plant system pressure is between
60 and 120 psi (414 and 827 kPa). The tank is
equipped with a pressure regulator to reduce the input
pressure to the 30 psi (207 kPa) required for the flux
feeding system. This pressure is set at the factory
before the machine is shipped. When the LN-8SE
with the 22-1/2 or 45 ft. (6.9 or 13.7 m) extension is
used, and the flux hose is long, set the air pressure at
45 psi (310 kPa) for 1/2 in. (12 mm) I.D. hose, and 55
psi (379 kPa) for 3/8 in. (9.5 mm) I.D. hose. Exact
pressure is indicated on the pressure gage. Air consumption is normally less than 1.5 cubic feet
(4.2 cubic meters) per minute of welding.
Connect the input air hose to the street elbow located
at the right side of the flux tank. A quick disconnect
should be installed between the elbow and the input
hose.
The air tank is equipped with a water and dirt separator. Water separated from the input air feeds down
through the long flux filled tube located at the input
connection. It is exhausted from the system through
the coiled tube below the flux tank. There is always a
small amount of air and possibly water coming out of
the end of this tube.

5. Use only clean, rust-free electrode wire.

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6. Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.

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A-18

LN-8

OPERATION

SECTION B-1

TABLE OF CONTENTS
-OPERATION SECTIONOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Controls and Their Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Constant Current Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
Constant Voltage Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-4
Avoiding Ground Lead Protector (GLP) Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-4
Wire Feed Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-5
Setting for CV or CC Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-6
Welding with a Constant Voltage Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-7
Welding with a Constant Current Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-7
Wire Reel Loading - 50 and 60 lb Coils (K303 Wire Reel Stand). . . . . . . . . . . . . . . . . . . .
B-8
Wire Reel Loading (K1524-1 Universal Wire Reel Stand) . . . . . . . . . . . . . . . . . . . . . . . . .
B-9
Feeding Electrode to the LN-8N or LN-8S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-11
Feeding Electrode to the LN-8NE or LN-8SE (With Extension) . . . . . . . . . . . . . . . . . .
B-11
Slow Acceleration Starting (Code 7926 and Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-12
Flux Tank Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-12

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SECTION B-1

LN-8

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B-2

OPERATION

Read and understand this entire section before
operating your machine.

SAFETY INSTRUCTIONS

CONTROLS AND THEIR
FUNCTIONS
CONSTANT CURRENT CONTROLS

WARNING

Operator controls for welding using a constant current
power source are illustrated in Figure B.1. Refer to the
figure and the following explanations of the controls.

ELECTRIC SHOCK can kill.

FIGURE B.1 – CONSTANT CURRENT CONTROLS

• Do not touch electrically live parts such
as output terminals or internal wiring.

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• Insulate yourself from the 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.

____________________________________

CURRENT
CONTROL

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WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

VOLTAGE
CONTROL

• Keep flammable material away.
• Do not weld, cut or gouge on containers
that have held combustibles.

____________________________________
ARC RAYS
can burn.

CIRCUIT
BREAKER
TRIGGER
INTERLOCK

• Wear eye, ear and body protection.

____________________________________

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Only qualified personnel should operate this equipment. Observe all safety information throughout this
manual.
WIRE FEED
DIRECTION
CONTROL

LN-8

GROUND LEAD
PROTECTOR
RESET BUTTON

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B-3

OPERATION

CURRENT CONTROL. Adjusts welding current by
controlling power source output.

VOLTAGE CONTROL. Adjusts arc voltage by controlling power source output voltage.

VOLTAGE CONTROL. Adjusts arc voltage by controlling wire feed speed.

CURRENT CONTROL. Adjusts wire feed speed to
control welding current.

TRIGGER INTERLOCK. With the switch in the OFF
position, the wire feed motor runs and the welding circuit is energized only when the gun trigger is pressed.
The operator must hold the trigger in from the start to
the finish of the weld. To stop the arc, the operator
releases the trigger and raises the gun from the work.
With the switch in the ON position, the operator holds
the trigger until the arc is established, then the trigger
can be released. When the welding is completed, the
operator raises the gun from the work to break the
arc.

FIGURE B.2 – CONSTANT VOLTAGE CONTROLS

WIRE FEED DIRECTION CONTROL. The direction
the electrode passes through the wire feeder is controlled by this switch. The electrode is fed through the
wire feeder in the same direction that the switch is
pointing.
CIRCUIT BREAKER. Protects the circuit from severe
wire feed motor overloads and short circuits. Press to
reset.
GROUND LEAD PROTECTOR RESET BUTTON.
The ground lead protector guards the ground lead in
the control cable from damage that can occur when
the electrode circuit touches the wire feeder frame
while the gun trigger is pressed. This button resets the
ground lead protector circuit.

CONSTANT VOLTAGE CONTROLS
Operator controls for welding using a constant voltage
power source that differ from the constant current controls are illustrated in Figure B.2. Refer to the figure
and the following explanations of the controls.

LN-8

CURRENT
CONTROLS
VOLTAGE
CONTROLS

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B-4

OPERATION

CIRCUIT PROTECTION
FIELD CIRCUIT FUSE. This 1/2 amp slow blow fuse,
located on the Relay PC board, protects the field circuit. It will blow if the field shorts or if one of the field
circuit components on the Relay PC board fails.
MOTOR THERMAL PROTECTION. The temperature
sensing thermal protector mounted in the motor opens
the relay circuit when the motor overheats because of
excessive loading or frequent triggering. This protects
the motor without nuisance tripping. The thermal protector automatically resets itself after the motor cools
sufficiently (may take 10-15 minutes). Reset time can
be shortened by cooling the motor with an air hose or
fan.
CIRCUIT BREAKER. The 5 amp circuit breaker located above the drive rolls normally trips only when an
overload occurs because of excessive loading in the
wire feed cable, or a defective motor or control component. After allowing a minute for cooling, push the
reset button and weld. If it trips again, be sure the wire
feed cable is clean and the proper size for the wire
diameter being fed. If it still trips, look for a defective
electrical component.

B-4

AVOIDING GROUND LEAD
PROTECTOR (GLP) ACTIVATION
The frame of the LN-8 wire feed unit and the drive
motor are grounded to the frame of the power source
by a lead in the control cable. An overload protector
prevents welding current from damaging this lead if
the electrode circuit touches the wire feeder frame
while the gun trigger is pressed.
When the protector is tripped, the welding contactor in
the power source will not close when the gun trigger is
pressed.
DO NOT allow the electrode to contact the case of the
wire feeder or the uninsulated part of the wire reel
stand when the gun trigger is activated.
Be sure that all work lead connections to the work
make tight metal-to-metal contact.
DO NOT allow excess input cable or work cable to be
placed closer than three feet from the wire feeder.
DO NOT coil excess input cable assembly or use a
coiled assembly as shipped from the factory. Instead,
loop the excess cable length back and forth in three to
six foot straight lengths. Coiling the input cable results
in a transformer action between the electrode
conductor cable and the ground lead in the
multiconductor control cable. This transformer action
can cause a current to flow in the ground lead which
will falsely activate the GLP circuit.
To reset the GLP circuit, press the white button above
the drive motor and to the right of the circuit breaker.

LN-8

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B-5

3. Install the drive roll and replace the clamping collar. Tighten the drive roll screw.

WIRE FEED ROLLS AND GUIDE
TUBES

4. Remove idle roll shaft screw. Install the idle roll
and idle roll shaft screw.

The drive rolls and guide tube kits are ordered separately. Refer to Figure B.3 and install these parts per
the following instructions:

5. Remove the large ingoing guide from the rear
brass block by loosening the locking screw.

1. Loosen the idle roll spring pressure screw.
6. Loosen the ingoing guide tube clamping screw.
Install the ingoing guide tube (which is stenciled
“in”) through the rear brass block. Tighten the
clamping screw.

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2. Remove the drive roll screw and clamping collar
from the drive shaft.

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B-5

OPERATION

FIGURE B.3 – WIRE FEED ROLLS AND GUIDE TUBE INSTALLATION
INGOING
GUIDE
TUBE

CLAMPING
COLLAR

DRIVE
DRIVE ROLL
ROLL SCREW

OUTGOING
GUIDE TUBE

CLAMPING
SCREW

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LOCKING
SCREW

IDLE
ROLL

LARGE
INGOING
GUIDE
IDLE ROLL
SPRING PRESSURE
SCREW

LOCKING
SCREW

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IDLE ROLL
SHAFT SCREW

LN-8

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B-6

OPERATION

7. Install the large ingoing guide into the rear brass
block and tighten the locking screw.

c. For wire sizes from 0.068 thru 0.120 in. (1.7
thru 3.0 mm) Idle roll pressure should be set
with wire in the system. For solid wire, the
indicator should be lined up with the “solid”
wire settings. For cored wire, the indicator
should be lined up with the “cored” wire settings. When using 7/64 in. (2.8 mm) diameter
‘Innershield’ wire, adjust the idle roll pressure
so that the indicator is between the 0.120 and
3/32 in. “cored” wire setting.

8. Install the outgoing guide tube with its plastic
insert through the front brass block. Tighten the
locking screw so the dog point goes into the
groove on the O.D. of the guide tube.
9. Set the drive roll spring pressure:
a. For wire sizes from 0.030 thru 0.052 in. (0.8
thru 1.3 mm) – With wire in the system, the
idle roll pressure indicator should be set to the
wire size shown on the “solid” side of the
nameplate. (For 0.030 in. (0.8 mm) solid wire,
set the pressure indicator to slightly less than
the 0.035 in. (0.9 mm) marking.) This setting
is a starting point and may have to be
changed depending upon the type of wire,
surface condition, lubrication, and hardness.
The optimum idle roll setting can be determined when there are wire stoppages. If the
wire “bird nests” between the drive roll and
the guide tube, the idle roll spring pressure is
too high. When properly set, the drive rolls will
slip during a stoppage. If the electrode is
removed from the cable, there will be a slight
waviness in the electrode for about a foot
beyond the slip marks on the electrode. If
there is no waviness, the pressure is set too
low.
b. For 1/16 in. (1.6 mm) solid or 0.062 in.
(1.6 mm) cored wire (using the 1/16 in. drive
roll) The idle roll pressure should be set with
wire in the system. For 1/16 in. (1.6 mm)
solid wire, the indicator should be lined up
with the “solid” 1/16 in. mark. For 0.062 in.
(1.6 mm) cored wire, adjust the idle roll pressure so that the indicator is lined up with the
“cored” 3/32 in. mark.

NOTE: The indicator settings for these larger wire
sizes are accurate enough so that there is no need to
readjust, unless the electrode is unusually soft.
The drive rolls are stamped with the wire size for
which they are designed. If a wire size is used
that is not stamped on the drive roll, the drive
rolls and guide tubes will have to be changed.

SETTING FOR CV OR CC POWER
SOURCES
The LN-8N and LN-8NE weld only with a constant
voltage (CV) power source. These machines can be
converted for constant current (CC) welding by
installing the proper parts.
The LN-8S and LN-8SE weld with either a CV or CC
power source. Set the equipment for either “CV” or
“CC” as appropriate per the following:

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NOTE: These indicator settings are accurate enough
so that there is no need to readjust unless the electrode is unusually soft.

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B-6

LN-8

1. If using a multi-process power source, set it up
per the instructions in the operating manual
shipped with the power source.
2. Turn the input power off and open the left panel.
Set the “CV-CC” switch located on the variable
voltage PC board inside the control box as
shown in Figure B.4.
3. There are two nameplates on top of each other
on the front of the wire feeder control box. Make
sure the correct nameplate for the power source
being used is on top.

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B-7

OPERATION
FIGURE B.4 – CV-CC SWITCH

B-7

Volts Control — Idealarc R3S Power Sources
Set the power source to the approximate voltage
required, per the R3S instruction manual. Make
final adjustments with the LN–8 ‘Volts’ control (or
the ‘Fine Voltage Control’ on the optional Line
Voltage Compensator).

CV-CC
SWITCH
VARIABLE
VOLTAGE
PC BOARD

Volts Control — SAM Power Sources
Set the power source for the approximate voltage
required, per the SAM instruction manual. Make
final adjustments with the LN-8 ‘Volts’ control.

2. Set the ‘Direction of Wire Feed’ switch so the
wire feeds out of the gun.

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If using the variable inductance control (see SAM
instruction manual), set the SAM ‘Current
Control’ as desired in the 8 o’clock range.

3. Adjust the electrical stickout and the actual
welding current and voltage as needed.

WELDING WITH A CONSTANT
CURRENT POWER SOURCE
1. Current and voltage adjustments

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Volts Control — All Power Sources
Set the welding voltage with the LN-8 ‘Volts’ control.
Amps Control — CC Power Sources
a. Place mode switch in the CC submerged arc
position.

VARIABLE
VOLTAGE
PC BOARD

b. Place power source output control toggle
switch in the ‘Output Control Remote’ position. Total current control is now at the LN–8.

WELDING WITH A CONSTANT
VOLTAGE POWER SOURCE

Amps Control — SAM Power Sources
Set the Current Control on the power source for
the approximate current required. Make final
adjustments with the LN-8 ‘Amps’ control.

1. Current and voltage adjustments

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Amps Control — All Power Sources
Set the welding current (or wire feed speed) with
the LN-8 Amps control.
Volts Control — DC-600 Power Source
a. Set the mode switch on the power source to
CV Innersheild or CV Subarc, as required.
b. Place power source output control toggle
switch in the ‘Output Control Remote’ position. Total voltage control is now at the LN–8.

LN-8

2. Set the ‘Direction of Wire Feed’ switch so the
wire feeds out of the gun.
3. Adjust the welding current and voltage while
welding as needed.

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B-8

FIGURE B.5 – LOADING A 50 OR 60 lb COIL

WIRE REEL LOADING – 50 AND
60 lb COILS (K303 WIRE REEL
STAND)

SPINNER
NUT
COVER
PLATE

MOUNTING A 50 OR 60 lb COIL
1. To remove the wire reel from its shaft, grasp the
spring loaded knob and pull out. This straightens
the knob so it seats into the shaft when released.
Remove the reel.

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2. Lay the reel flat on the floor. Loosen the spinner
nut and remove the cover plate. See Figure B.5.

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B-8

OPERATION

SLOTS

3. Place the coil of electrode on the reel so it
unwinds as the reel rotates clockwise. DO NOT
cut the tie wires at this time.
4. Be sure the coil is placed so the spring loaded
arms will not interfere with the later removal of
the coil tie wires.
5. When loading the electrode, be certain the coil is
placed on the reel so the spring loaded arms are
at the center of the slots in the cardboard coil liner.
This provides the positive compression of the coil
sides needed for trouble-free wire feeding.

CARDBOARD
COIL
LINER

COIL
TIE
WIRE
REEL

SPRING
LOADED
ARM

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6. Put the cover plate on the reel so the four arms
of the cover plate straddle and are in line with the
spring loaded arms of the reel.
7. Tighten the cover as much as possible by hand.
DO NOT hammer on the spinner nut arms.

CAUTION
Always be sure the free end of the coil is securely
held while the tie wires are being cut and until the wire
is feeding through the drive rolls. Failure to do this will
result in “back lashing” of the coil, which may tangle
the wire. A tangled coil will not feed. It must be untangled or discarded.

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____________________________________

LN-8

8. Cut and remove only the tie wire holding the free
end of the coil. Insert the free end into one of the
holes in the cover and secure it by bending it
back. Cut and remove the remaining tie wires.
9. Replace the reel on the wire reel stand. Grasp
the shaft knob, pull it out and swing it across the
reel hub, locking the reel in place.

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B-9

6. Set one of the Readi-Reel inside cage wires on
the slot in the retaining spring tab.

WIRE REEL LOADING (K1524-1
UNIVERSAL WIRE REEL STAND)

7. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.

TO MOUNT A 30 lb (14 kg) READI-REEL
PACKAGE (USING THE MOLDED PLASTIC
K363-P READI-REEL ADAPTER):

8. Slide the cage all the way onto the adapter until
the retaining spring “pops up” fully.

The spindle should be located in the LOWER mounting hole.

CAUTION

1. Depress the Release Bar on the Retaining Collar
and remove it from the spindle. See Figure B.6.

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2. Place the Adapter on the spindle.
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B-9

OPERATION

3. Re-install the Retaining Collar. Make sure that
the Release Bar “pops up” and that the collar
retainers fully engage the retaining groove on the
spindle.

Check to be sure the Retaining Spring has fully returned
to the locking position and has SECURELY locked the
Readi-Reel cage in place. The Retaining Spring must
rest on the cage, not the welding electrode.

____________________________________

4. Rotate the spindle and adapter so the retaining
spring is at the 12 o’clock position.

9. To remove the Readi-Reel from the Adapter,
depress the retaining spring tab with a thumb
while pulling the Readi-Reel cage from the molded
adapter with both hands. Do not remove the
Adapter from the spindle.

5. Position the Readi-Reel so that when it rotates
the wire is de-reeled from the bottom of the coil.

FIGURE B.6 – READI-REEL MOUNTING

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ADAPTER
2 IN. O.D.
SPINDLE

RETAINING
SPRING

BRAKE
HOLDING
PIN

RETAINING
COLLAR

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GROOVES

READI-REEL
INSIDE CAGE
WIRES
LN-8

RELEASE
BAR

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B-10

OPERATION

TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS
(12 in./300 mm DIAMETER) OR 14 lb (6 kg)
INNERSHIELD COILS:

FIGURE B.7 – K1504-1 COIL REEL
SPINNER NUT

The spindle should be located in the lower mounting
hole.

COVER
PLATE

[For 8 in. (200 mm) spools, a K468 spindle adapter
must first be slipped onto the spindle.]
[For 13 to 14 lb (6 kg) Innershield coils, a K435 Coil
Adapter must be used.]

SLOTS

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1. Depress the Release Bar on the Retaining Collar
and remove it from the spindle.

CARDBOARD
COIL LINER

2. Place the spool on the spindle, making certain
the spindle brake pin enters one of the holes in
the backside of the spool. Be certain the wire
comes off the reel in a direction so as to de-reel
from the bottom of the coil.

COIL

3. Re-install the Retaining Collar. Make sure that
the Release Bar “pops up” and that the collar
retainers fully engage the retaining groove on the
spindle.

TIE WIRE
SPRING
LOADED ARM

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TO MOUNT A 50 to 60 lb (22.7 to 27.2 kg) COIL:
(USING K1504-1 COIL REEL) (FOR 50 to 60 lb
READI-REELS A K438 READI-REEL ADAPTER
MUST BE USED.)
The spindle should be located in the UPPER mounting hole.
1. With the K-1504-1 Coil Reel mounted on the 2 in.
(51 mm) spindle (or with reel laying flat on the
floor) loosen the spinner nut and remove the reel
cover. See Figure B.7.
2. Before cutting the tie wires, place the coil of electrode on the reel so it unwinds from the bottom
as the reel rotates.

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3. Tighten the spinner nut against the reel cover as
much as possible by hand, using the reel cover
spokes for leverage. DO NOT hammer on the
spinner nut arms.
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REEL

CAUTION
Always be sure the free end of the coil is securely
held while the tie wires are being cut and until the wire
is feeding through the drive rolls. Failure to do this will
result in “backlash” of the coil, which may tangle the
wire. A tangled coil will not feed, so it must either be
untangled or discarded.

____________________________________

4. Cut and remove only the tie wire holding the free
end of the coil. Hook the free end around the rim
of the reel cover and wrap it around to secure.
Cut and remove the retaining tie wires.

LN-8

5. Be sure the coil is engaged with the spindle
brake pin and the Release Bar and Retaining
Collar “pops up” and that the collar retainers fully
engage the retaining groove on the spindle.

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B-11

FEEDING ELECTRODE TO THE LN-8N OR
LN-8S

4. Pull the plastic hand crank handle to the out position in the arm.

1. Turn the reel until the free end of the electrode is
accessible.

5. Pull the shaft and drive roll assembly to the out
position.

2. While tightly holding the electrode, cut off the
bent end and straighten the first six inches. Cut
off the first inch. (If the electrode is not properly
straightened, it may not feed or may not go into
the outgoing guide tube causing a “birdnest”.)

6. Apply downward pressure to the idler roll pressure arm. Maintain this pressure and start cranking the wire thru the system. Keep the conductor
cable as straight as possible during the loading
operation. This will facilitate cranking the wire
through.

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3. Insert the free end through the incoming guide
tube.

7. Crank until the wire touches the drive roll and
then pull the gun trigger. This will start the drive
rolls and feed the wire the rest of the way
through the cable and gun assembly.

4. Press the gun trigger and push the electrode into
the drive roll.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

• When inching with the gun trigger,
electrode and drive mechanism are
“hot” to work and ground.

____________________________________

• When inching with the gun trigger,
electrode and drive mechanism are
“hot” to work and ground.

____________________________________

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5. Inch the electrode through the gun.

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B-11

OPERATION

8. Push the plastic of the hand crank to the in
position, as shown in Figure B-8.

FEEDING ELECTRODE TO THE LN-8NE
OR LN-8SE (WITH EXTENSION)
1. Slide the ingoing guide tube of the hand crank to
the forward position.
2. Remove start end of coil from the hole in the wire
reel cover, straighten the first six inches of the
wire and then insert this end into the ingoing
guide tube. Push at least one foot of wire
through.
3. Pull the ingoing guide tube back to the rear position and rotate 90˚ so that it will remain in this
position during the cranking operation.

LN-8

9. Shift the ingoing guide tube to the forward
position.
FIGURE B.8 – HAND CRANK POSITION
BRASS
BLOCKS

HAND CRANK
ARM

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B-12

OPERATION

SLOW ACCELERATION STARTING
(CODE 7926 AND ABOVE)

FLUX TANK LOADING

The LN-8 has the capability of optimum starting for different processes. This is accomplished by designing
the LN-8 to start with two different speeds of controlled acceleration. As shipped, the unit is connected
for fast acceleration, which is best for most open arc
procedures. The slower acceleration may be more
desirable for long stickout applications and most submerged arc procedures. If the electrode being used
does not give satisfactory starting because of “stubbing” or “blast off”, the slower acceleration can be
obtained by modifying the LN-8 as follows:
1. Turn off the control power to the LN-8 at the
power source.
2. Remove the screws holding the control section
cover in place and swing open.
3. Switch circuit #1 of S1 on the Control PC board
from position “F” to position “S”.
4. Reassemble.

B-12

Either turn off the incoming air line or remove the
quick disconnect if one has been installed. Slightly
loosen the tank cap and let the air in the tank escape
in the holes in the side of the cap. After pressure has
been released, remove the cap from the tank. Using
the funnel provided, put 100 pounds of flux in the tank.
It is very important that only new or properly reclaimed
flux be put in the tank. Coarse particles and/or magnetic particles will stop the flux feeding process. New
Lincoln flux is properly screened at the factory. All
reclaimed flux must be separately screened through a
vibrating screen with 0.065 to 0.075 in. openings and
be put through a magnetic separator. The K310 vibrated screen and K58 magnetic separator are available
for this purpose. The screen in the funnel supplied
with the tank has much larger openings and its only
purpose is to keep paper and slag out of the tank.
Screw the tank cap back on and tighten hand tight.
Reconnect the incoming air supply.
There will always be a small amount of air and possibly drops of water coming out of the end of the tube
coiled under the tank. This is an automatic disposal
system in case the plant air has water and dirt in it.

LN-8

ACCESSORIES

SECTION C-1

TABLE OF CONTENTS
-ACCESSORIES SECTIONAccessories............................................................................................................................. Section C
General................................................................................................................................
C-2
K163 Undercarriage (Requires K303, K377, or K378) ..................................................
C-3
K178 Mounting Platform ................................................................................................
C-3
K261 Meter Kit...............................................................................................................
C-3
K202 Burnback Kit.........................................................................................................
C-3
K58 Magnetic Separator ...............................................................................................
C-3
K119 Gravity Feed Flux Cone .......................................................................................
C-3
K310 Flux Screen ..........................................................................................................
C-3
K320 Flux Tank .............................................................................................................
C-3
K161 Mechanized Travel Power Pack...........................................................................
C-3
K240 Contactor Kit ........................................................................................................
C-4
K317 Dual Process Kit (No Polarity Change) ................................................................
C-4
K318 Dual Process Contactor Kit (With Polarity Changes) ...........................................
C-4
Reel Mounting Accessories.................................................................................................
C-4
K303 50 to 60 lb (22.7 to 27.2 kg) Wire Reel Stand ......................................................
C-4
K1524-1 Universal Reel Stand and Base Assembly .....................................................
C-4
K162 Spindle for Mounting Readi-Reels and 10 thru 30 lb
(4.5 thru 13.5 kg) Spools ............................................................................................
C-4
K377 Small Mounting Stand for Readi-Reel Coils or 10 thru 30 lb
(4.5 thru 13.5 kg) Spools with 2 in. (50 mm) I.D .........................................................
C-4
K378 Small Mounting Stand for 13 to 14 lb (6.0 to 6.4 kg) Innershield Coils ................
C-4
M11514 Wire Reel Dust Shield Door for K303 ..............................................................
C-4
Welding Guns......................................................................................................................
C-5
Innershield Guns ...........................................................................................................
C-5
Submerged Arc Guns ....................................................................................................
C-5
GMAW Guns .................................................................................................................
C-5
Welding Gun Accessories ...................................................................................................
C-5
K70 Fillet Guide .............................................................................................................
C-5
K110 Hand Travel Unit ..................................................................................................
C-5
K62 Squirtmobile ...........................................................................................................
C-5
Constant Current Conversion Parts ....................................................................................
C-5

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SECTION C-1

LN-8

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C-2

ACCESSORIES

C-2

GENERAL
The following is a list of the accessories that can be
used with the LN-8 wire feeder unit.

A detailed description of each item is given later in the
section.

TABLE C.1 – LN-8 WIRE FEEDER ACCESSORIES
Product Number
K163

Name
UNDERCARRIAGE

K178

MOUNTING PLATFORM

K261

METER KIT

K202

BURNBACK KIT

K58

MAGNETIC SEPARATOR

K119

GRAVITY FEED FLUX CONE

K310

FLUX SCREEN

K320

FLUX TANK

K161

MECHANIZED TRAVEL POWER PACK

K240

CONTACTOR KIT

K317

DUAL PROCESS KIT (NO POLARITY CHANGE)

K318

DUAL PROCESS CONTACTOR KIT (WITH POLARITY CHANGES)

K303

50 THRU 60 lb (22.7 THRU 27.2 kg) WIRE REEL STAND

K1524-1

UNIVERSAL REEL STAND AND BASE ASSEMBLY

K162

SPINDLE FOR MOUNTING READI-REELS AND 10 THRU 30 lb
(4.5 THRU 13.5 kg) SPOOLS

K377

SMALL MOUNTING STAND FOR READI-REEL COILS OR 10 THRU 30 lb
(4.5 THRU 13.5 kg) SPOOLS WITH 2 in. (50 mm) I.D.

K378

SMALL MOUNTING STAND FOR 13-14 lb. (6.0-6.4 kg) INNERSHIELD COILS

M11514

WIRE REEL DUST SHIELD DOOR FOR K303

K112

SUBMERGED ARC WELDING GUN - 500 AMPS

K113

SUBMERGED ARC WELDING GUN - 600 AMPS

K114

SUBMERGED ARC WELDING GUN - 600 AMPS

K115

INNERSHIELD WELDING GUN - 450 AMPS

K116

INNERSHIELD WELDING GUN - 400 AMPS

K126

INNERSHIELD WELDING GUN - 350 AMPS

K497

MAGNUM GMA WELDING GUN - 200 AMPS

K471

MAGNUM GMA WELDING GUN - 300 AMPS

K527

MAGNUM GMA WELDING GUN - 400 AMPS

K70

FILLET GUIDE

K110

HAND TRAVEL UNIT

K62

SQUIRTMOBILE
CONSTANT CURRENT CONVERSION PARTS

LN-8

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C-3

ACCESSORIES

K163 UNDERCARRIAGE
(REQUIRES K303, K377, OR K378)

K58 MAGNETIC SEPARATOR

The undercarriage includes casters, wheels, a handle,
and related hardware. Casters are mounted at the
front and wheels are mounted at the rear of the platform. The handle is bolted to the front of the platform
so the wire feeder can be tilted back and wheeled like
a two-wheel truck. Installation sheet M13424 is provided with the undercarriage.

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K178 MOUNTING PLATFORM
This is a turntable type platform for mounting the LN-8
to the top of Idealarc power sources. Bolt the platform
to the lift bail per the instructions supplied with the
platform.

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K119 GRAVITY FEED FLUX CONE
The flux cone is manual feed attachment for the K112
and K113 sub-arc guns that is used instead of the
continuous feed flux system. The flux cone attaches to
the gun using the screws provided. The cone also
includes a new clamp to be used to hold the trigger
pod to the gun. Use it in place of the clamp shipped
with the gun.

K310 FLUX SCREEN
All LN-8 wire feed units with code no. 7580 to 7925
come equipped with a factory calibrated Speedmeter
Trimmer PC board and meter kit receptacle prepared
to accept the optional K261 speed-ammeter voltmeter
(analog) kit. LN-8 wire feed units no. 7926 and above
come with the speedmeter trimmers incorporated into
the Control PC board.

This kit is useful to help prevent the electrode from
sticking in the crater at the end of the weld in two
types of welding applications:

The unit was designed to fit the top of either the standard fill funnel or the K58 magnetic separator. The
unit has a steel screen with 0.065 to 0.075 in. openings and an air vibrator attached to the frame. The
vibrator can be used with air line pressures ranging
from 20 through 100 psi.
For ease of handling, the user should connect the
incoming air line to the 1/8 in. pipe elbow with the aid
of a quick disconnect type air coupling.
It is very important that reclaimed flux to be used in
the continuous flux feeding system be passed through
the K310 screen or its equivalent.

K320 FLUX TANK
1. Welding with small diameter wire [0.035 thru 1/16
in. (0.9 thru 1.6 mm)] at fast wire feed speed
when there is a tendency to overrun the wire.
2. When the semiautomatic gun is mounted in a fixture or on the K62 Squirtmobile in such a manner
that it cannot be lifted from the work at the end of
the weld.

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Useful with any submerged arc equipment. The unit
removes foreign magnetic particles from reused submerged arc welding flux. Operating instructions are
included with the kit.

K261 METER KIT

K202 BURNBACK KIT

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C-3

The kit delays the dropout of the contactor allowing
the electrode to burnback from the crater at the end of
the weld. The delay time is adjustable for optimum
burnback for different sizes, processes, and procedures. Installation instructions are shipped with the kit.

The flux tank is available to permit the LN-8 to be
used for submerged arc welding. Installation instructions are shipped with the kit.

K161 MECHANIZED TRAVEL
POWER PACK
The power pack supplies the power needed by the
K110 hand travel unit or the K62 Squirtmobile when
used with the K114 sub-arc welding gun. Complete
installation instructions are shipped with the kit.

LN-8

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C-4

K240 CONTACTOR KIT
Output contactor with pilot relay to make the electrode
‘cold’ when not welding. Must be ordered when using
the LN-8 with SA-750, SAE, TM, R3M and R3R
Idealarcs. Contactor kits are rated at 600 amps maximum, and cannot be paralleled with each other.

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K317 DUAL PROCESS KIT
(NO POLARITY CHANGE)
The Dual Process Kit is a transfer device that connects two wire feeders to a single power source and
enables each wire feeder to weld a different procedure without changing any of the dials. When used
with the DC-600, the wire feeders can be set for different modes; CV Innershield or CV Submerged Arc.
Both wire feeders will operate at the same polarity.

K318 DUAL PROCESS CONTACTOR KIT
(WITH POLARITY CHANGES)
The Dual Process Contactor Kit permits the connection of two wire feeders to a single power source and
enables each wire feeder to weld at a different procedure and polarity without changing any dials or switches. When used with the DC-600, the wire feeders can
be set for different modes; CV Innershield or CV
Submerged Arc. The kit can also be connected to
operate with the same polarity on each wire feeder.

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K363P
K435
K468
K1504-1
K438

30 lb Readi-Reel Adapter
Spindle Adapter for 14 lb coils
Spindle Kit
60 lb Wire Reel
60 lb Readi-Reel Adapter

K162 SPINDLE FOR MOUNTING
READI-REELS AND 10 THRU 30 lb
(4.5 THRU 13.5 kg) SPOOLS
For use with the K303 wire reel stand. To mount this
spindle kit, remove the shaft from the standard 50 to
60 lb (22.5 to 27.2 kg) wire coils from the mounting
framework. Install the spindle per the instructions
shipped with the kit.

K377 SMALL MOUNTING STAND FOR
READI-REEL COILS OR 10 THRU 30 lb
(4.5 THRU 13.5 kg) SPOOLS WITH 2 in.
(50 mm) I.D.
This assembly includes a wire reel spindle (similar to
the K162 spindle) attached to a small frame. The unit
is supplied with the K363 Readi-Reel Adapter for
using the Lincoln “Readi-Reel Electrode Coils”.
Without the adapter, the unit is capable of handling
spools with a 2 in. I.D., a 12 in. maximum O.D., and a
4 in. width. The spindle has an adjustable breaking
system.

K378 SMALL MOUNTING STAND FOR
13 TO 14 lb (6.0 TO 6.4 kg)
INNERSHIELD COILS

REEL MOUNTING ACCESSORIES
K303 50 TO 60 lb (22.7 TO 27.2 kg)
WIRE REEL STAND
This assembly includes a framework to which is
attached a 50 to 60 lb (22.7 to 27.2 kg) wire reel, a
mounting spindle, a lift bail, and a cable clamp for fastening the input cable assembly.

K1524-1 UNIVERSAL REEL STAND
AND BASE ASSEMBLY
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C-4

ACCESSORIES

The wire reel stand comes with a 2 in. spindle. With
the addition of the proper spindle and Readi-Reel
adapters, it can accomodate various sizes of coils,
spools, and Readi-Reels.

This assembly includes the smaller frame as used in
the K377 and the fully enclosed canister system for
derailing of the 14 lb coil. This system has a fixed
brake for the 14 lb coil.

M11514 WIRE REEL DUST SHIELD DOOR
FOR K303
In extremely dusty and dirty locations, this door kit can
be added to those units having a dust shield kit
(S14543). This door kit includes a hinged door and
sliding bottom seal. When these parts are attached to
the reel support per the instructions included, the unit
becomes a completely enclosed housing. Order part
no. M11514.

LN-8

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C-5

ACCESSORIES

WELDING GUNS

WELDING GUN ACCESSORIES

INNERSHIELD GUNS

K70 FILLET GUIDE

The K126 gun and cable assembly is recommended
for most Innershield electrodes at up to 350 amps.

The fillet guide is designed to help guide the K114
sub-arc gun so the operator can make more uniform
horizontal fillet welds with less effort. It consists of a
vertical plate roller guide and rear wheel assembly.
Once the roller guide and rear wheel are adjusted, the
weld is easily made by gently pushing the gun into the
fillet. The operator does not have to constantly control
the drag of the flux cone against the vertical plate or
carefully watch the angle of the gun.

The K115 gun and cable assembly is recommended
for up to 450 amps.

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The K116 gun and cable assembly is recommended
for up to 600 amps.

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C-5

NOTE: LinconditionerTM guns are recommended for
locations where smoke accumulation is a problem and
conventional exhaust systems are ineffective. The
available smoke removal type Innershield guns and
vacuum units can be used in these locations.
Instructions are shipped with the equipment.

SUBMERGED ARC GUNS

K110 HAND TRAVEL UNIT
The mechanized travel unit can be attached to the
K114 sub-arc gun and is used to obtain controlled
travel speeds ranging from 7 to 60 inches. Since the
hand travel unit derives its control power from a magamp source, a K161 power pack is required for this
mode of operation.

The K112 gun and cable assembly is recommended
for welding up to 500 amps.

K62 SQUIRTMOBILE

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The K113 gun and cable is recommended for use up
to 600 amps.
The K114 gun and cable assembly is a 600 amp gun
that includes a flux valve and receptacle for the K110
or K62.

GMAW GUNS
An expanding line of Magnum GMA gun and cable
assemblies are available to allow welding with solid
and cored electrodes using the GMAW process. See
the appropriate Magnum literature for descriptions of
the 100-500 ampere air cooled gun and cables that
are available. Gun cable lengths range from 10 to
25 ft. (3.0 to 7.5 m) and feed electrode sizes 0.023 to
3/32 in. (0.6 to 2.4 mm).

The Squirtmobile is a self-propelled trackless carriage
that carries the K114 sub-arc gun on long welds for
automatic welder economy without high fixture costs.
To use the LN-8S or LN-8SE with the Squirtmobile,
install the K161 mechanized travel power pack.

CONSTANT CURRENT
CONVERSION PARTS
To convert the LN-8N or LN-8NE for welding with a
constant current power source, purchase a variable
voltage PC board L5039, and constant current dial
plate (M12230 for LN-8N and LN-8S models, M13148
for LN-8F models above code 7580).

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NOTE: Magnum GMA welding guns require a K466-1
connector for use with an LN-8 wire feeder.

LN-8

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C-6

NOTES

LN-8

C-6

MAINTENANCE

SECTION D-1

TABLE OF CONTENTS
-MAINTENANCE SECTIONMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Wire Reel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Wire Drive Motor and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2
Gun and Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2

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SECTION D-1

LN-8

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D-2

MAINTENANCE

ROUTINE MAINTENANCE

PERIODIC MAINTENANCE

DRIVE ROLLS AND GUIDE TUBES

CONTROL BOX

After feeding every coil of wire, inspect the drive roll
section. Clean the assembly as necessary. Do not use
solvent to clean the drive roll assembly as it may wash
the lubricant out of the bearings. The drive rolls and
guide tubes are stamped with the wire sizes they will
feed. If a wire size other than that stamped on the rolls
is to be used, the rolls and guide tubes must be
changed.

Every six months, open and inspect the control section. The accumulated dirt should be gently blown off
all the electrical components. Be sure the air that is
used is dry. Check all relay contacts.

The drive rolls for 0.068 and 0.120 in. (1.7 thru
3.0 mm) wire have a double set of teeth so they can
be reversed for additional life. Between the two
knurled rolls is a shim washer which limits the damage
to the electrode if wire feeding problems occur. Drive
rolls for 1/16 in. (1.6 mm) and smaller wire have no
teeth and are not reversible.
Refer to the instructions included with the drive roll kit
for installation and replacement of the drive rolls on
the wire feeder.

WIRE DRIVE MOTOR AND GEARBOX
Every year, inspect the gearbox and coat the gear
teeth with a moly-disulfide filled grease. Do not use
graphite grease.
Every six months, check the motor brushes. Replace
them if they are less than 1/4 in. (6.4 mm) long.

GUN AND CABLE MAINTENANCE
For instructions on periodic maintenance for the welding gun and cables, refer to the manual for your specific model of welding gun.

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WIRE REEL MOUNTING

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D-2

To prolong the life of the reel shaft on the 50 to 60 lb
coils, periodically coat it with a thin layer of grease. No
maintenance to the two position brake is required. If
the brake shoe wears through to metal, replace the
brake assembly.

LN-8

THEORY OF OPERATION

SECTION E-1

TABLE OF CONTENTS
-THEORY OF OPERATION SECTIONTheory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-2
Power Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-2
Gun Trigger and 1CR Relay Contact Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-3
Variable Voltage Board, Meter Shunt, Wire Speed and Remote Output Controls . . . . . . .
E-4
SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-5

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SECTION E-1

LN-8

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E-2

THEORY OF OPERATION
FIGURE E.1 – POWER INPUT CIRCUITS

REMOTE
OUTPUT
CONTROL

#21

#75
#76
#77

#567

VARIABLE VOLTAGE
BOARD

ELECTRODE
METER
SHUNT

WIRE FEED
SPEED CONTROL

CIRCUIT
BREAKER
INPUT
RECEPTACLE

#32

#32A

ARMATURE

CONTROL
BOARD

WIRE
FEED
MOTOR

THERMAL
CIRCUIT
BREAKER

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#31
#2
&
#4

2 OHMS

C
O
N
T
A
C
T
O
R

#3
2
A

#531

RELAY
BOARD

CONTROL

GUN
CABLE
RECEPTACLE

OPTIONAL
BURNBACK
BOARD

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GLP

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FIELD

FUSE

REED
SWITCH

TRIGGER
TRANS.

GENERAL DESCRIPTION
The LN-8 is a semiautomatic wire feeder
designed for Innershield (FCAW) and
gas metal arc processes with the appropriate accessories. It is also suitable for
constant voltage (CV) submerged arc
welding processes. With the optional
variable voltage board installed the LN-8
can be used with constant current (CC)
procedures. The wire feed speed and
welding power source output can be
controlled from the LN-8.

POWER INPUT CIRCUITS
The 115VAC is applied (usually from the
welding power source) via the input

WIRE
FEED
SWITCH

INTERLOCK
SWITCH

receptacle, through the circuit breaker
and 2 ohm resistor to the control board,
the relay board, and the trigger transformer.
The 24VAC developed at the trigger
transformer is rectified on the relay
board and applied to the gun trigger circuit which controls the 1CR relay.
The 115VAC that is applied to the control board is rectified and controlled by
SCRs (See SCR Operation) and
applied to the armature of the wire feed
motor.
The relay board rectifies the 115VAC
and applies it to the field winding of the
wire feed motor.

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
LN-8

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E-3

THEORY OF OPERATION
FIGURE E.2 – GUN TRIGGER AND 1CR CONTACT CONTROL CIRCUITS

REMOTE
OUTPUT
CONTROL

#21

#75
#76
#77

#567

VARIABLE VOLTAGE
BOARD

ELECTRODE
METER
SHUNT

WIRE FEED
SPEED CONTROL

CIRCUIT
BREAKER
INPUT
RECEPTACLE

#32

#32A

ARMATURE

CONTROL
BOARD

WIRE
FEED
MOTOR

THERMAL
CIRCUIT
BREAKER

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#31
#2
&
#4

2 OHMS

C
O
N
T
A
C
T
O
R

#3
2
A

#531

RELAY
BOARD

CONTROL

GUN
CABLE
RECEPTACLE

OPTIONAL
BURNBACK
BOARD

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GLP

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FIELD

FUSE

REED
SWITCH

TRIGGER
TRANS.

GUN TRIGGER AND 1CR
RELAY CONTACT
CONTROL CIRCUITS
When the gun trigger switch is activated (closed) the 1CR relay is energized.
Three sets of isolated contacts incorporated within the 1CR relay perform
several functions. One set of contacts
completes the circuit to energize the
wire feed motor armature and also the
auxiliary circuit #7 and #32A. Another
set of contacts control the motor field
circuit polarity which, along with the
wire feed switch, dictate the wire feed
direction. The third set of contacts
control the #2 and #4 contactor circuit

WIRE
FEED
SWITCH

INTERLOCK
SWITCH

which enables the power source welding output. The #2 and #4 contactor
circuit is passed through the optional
burnback board which delays the
“opening” of the circuit and prevents
the electrode from “sticking” in the
weld puddle.
The interlock switch, reed switch,
ground lead protector (GLP), and thermal circuit breaker are all incorporated
in the gun trigger circuit. In case of a
fault condition, the GLP or thermal circuit breaker will disable the trigger circuit. The interlock switch and reed
switch enhance the gun trigger circuitry
by allowing the operator to release the
trigger button and continue welding.

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
LN-8

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E-4

THEORY OF OPERATION
FIGURE E.3 – VARIABLE VOLTAGE BOARD, METER SHUNT, WIRE SPEED,
AND REMOTE OUTPUT CONTROLS

REMOTE
OUTPUT
CONTROL

#21

#75
#76
#77

#567

VARIABLE VOLTAGE
BOARD

ELECTRODE
METER
SHUNT

WIRE FEED
SPEED CONTROL

CIRCUIT
BREAKER

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INPUT
RECEPTACLE

#32

#32A

ARMATURE

CONTROL
BOARD

WIRE
FEED
MOTOR

THERMAL
CIRCUIT
BREAKER

#31
#2
&
#4

2 OHMS

C
O
N
T
A
C
T
O
R

#3
2
A

#531

FIELD

FUSE
RELAY
BOARD

CONTROL

GUN
CABLE
RECEPTACLE

OPTIONAL
BURNBACK
BOARD

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GLP

REED
SWITCH

TRIGGER
TRANS.

VARIABLE VOLTAGE
BOARD, METER SHUNT,
WIRE SPEED AND
REMOTE OUTPUT
CONTROLS
The optional variable voltage board
enables the LN-8 to be used with a constant current power source. The variable voltage board monitors the arc
voltage via leads #21 and #567 and
modifies the wire feed speed according
to arc voltage variations and requirements.

WIRE
FEED
SWITCH

INTERLOCK
SWITCH

operator. The control board adjusts the
armature voltage applied to the wire
feed motor to change the motor speed.
The remote output control permits
power source control from the LN-8
unit. The remote control is coupled to
the welding power source via leads #75,
#76, and #77 through the input
receptacle.
The electrode meter shunt, which is
connected to and also in series with the
gun connector block, senses the welding current and arc voltage. This information is used by the variable voltage
board and also the optional meter kit.

The wire speed control dictates to the
control board the directives of the

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
LN-8

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E-5

THEORY OF OPERATION
FIGURE E.4 – SILICON-CONTROLLED RECTIFIER OPERATION

INPUT

CATHODE
OUTPUT
ANODE

GATE
GATE

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NOTE:

AS THE GATE PULSE IS
APPLIED LATER IN THE
CYCLE, THE SCR OUTPUT
IS DECREASED.

SCR OPERATION
A silicon controlled rectifier (SCR) is a
three terminal semi-conductor device
used to control currents to a load. Refer
to Figure E.4. An SCR acts very much
like a switch. When a gate signal is
applied to the SCR it is turned ON and
there is current flow from anode to cathode. In the ON state the SCR acts like a
closed switch. When the SCR is turned
OFF there is no current flow, thus the
device acts like an open switch. As the
name suggests, the SCR is a rectifier,
so it passes current only during positive
half cycles of the AC supply, The positive half cycle is the portion of the sine
wave in which the anode of the SCR is
more positive than the cathode.
When an AC supply voltage is applied
to the SCR, the device spends a certain
portion of the AC cycle time in the ON
state and the remainder of the time in
the OFF state. The amount of time
spent in the ON state is controlled by
the gate.

LN-8

An SCR is fired by a short burst of current into the gate. This gate pulse must
be more positive than the cathode voltage. Since there is a standard PN junction between the gate and cathode, the
voltage between these terminals must
be slightly greater than 0.6 VDC. Once
the SCR has fired, it is not necessary to
continue the flow of gate current. As
long as current continues to flow from
anode to cathode the SCR will remain
on. When the anode to cathode current
drops below a minimum value, called
holding current, the SCR will shut off.
This normally occurs as the AC supply
voltage passes through zero into the
negative portion of the sine wave. If the
SCR is turned on early in the positive
half cycle, the conduction time is longer,
resulting in greater SCR output. If the
gate firing time is later in the cycle the
conduction time is less, resulting in
lower SCR output.

E-5

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E-6

NOTES

LN-8

E-6

TROUBLESHOOTING AND REPAIR

SECTION F

TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTIONTroubleshooting and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
How to Use Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-4
LN-8 Electrical Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-10
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-12
Trigger Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-12
Internal Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-14
1CR Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-17
Drive Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-20
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-24
Potentiometer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-24
Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-26
Ground Lead Protector Push Button Switch Replacement. . . . . . . . . . . . . . . . . . . . . .
F-28
Trigger Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-30
PC Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-32
Wire Drive Assembly and Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
F-35
Retest After Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-40

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SECTION F

LN-8

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F-2

TROUBLESHOOTING AND REPAIR
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.
__________________________________________________________________________

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This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: function problems, feeding problems, and welding problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF
ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject
component is either good or bad. If there
are a number of possible components,
check the components in the order listed to
eliminate one possibility at a time until you
locate the cause of your problem.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter. Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 1-800-833-9353.

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_____________________________________________________________

LN-8

F-2

TROUBLESHOOTING & REPAIR
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.

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CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.

- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow
proper failure analysis.
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.

2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.

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3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:

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F-3

PC BOARD TROUBLESHOOTING PROCEDURES

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F-3

a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.

PC board can be damaged by static electricity.

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.

- Remove your body’s static
charge before opening the staticshielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
to a grounded part of the
equipment frame.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.

6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

LN-8

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F-4

TROUBLESHOOTING AND REPAIR
TROUBLESHOOTING GUIDE
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FUNCTION PROBLEMS
No wire feed or arc voltage when
the gun trigger is activated. The
drive rolls do not turn. The LN-8
appears “dead”.

1. Check the Ground Lead
Protector (GLP). Reset if
necessary.
2. Check the circuit breaker. Reset
if necessary.

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3. Make sure 115VAC is being
applied to the LN-8 at the input
receptacle. Pin “C” lead #31 and
pin “D” lead #32.

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6. If the switch on the variable
board is in the “VV” position,
make sure the power source is
set for an open circuit voltage of
30VDC or more.

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F-4

4. Check the 1/2 amp fuse located
on the relay board. Replace if
necessary.

1. Check for loose or faulty connections between the input
receptacle, the circuit breaker,
and the 2 ohm resistor. See
wiring diagram.
2. Check the 2 ohm resistor.
Replace if faulty.
3. Perform the Trigger
Transformer Test.
4. Perform the Internal Voltage
Test.

5. Perform the 1CR Relay Test.
5. If the LN-8 has a variable voltage
board and the power source is a 6. Check the relay board. Replace
constant current supply, check to
if faulty.
make sure the switch on the variable voltage board is in the “VV” 7. Check the variable voltage board
position.
(if used). Replace if faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.

LN-8

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TROUBLESHOOTING AND REPAIR

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

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RECOMMENDED
COURSE OF ACTION

FUNCTION PROBLEMS (Continued)
The wire feeds when the gun trigger is activated but there is no arc
voltage.

1. Check the welding cables for
loose or faulty connections.

1. The 1CR relay, located on the
power board, may be faulty.
Check or replace. Note: The
relay may operate but the individual contacts may not be functioning properly.

2. Put a jumper wire from #2 to #4
on the power source terminal
strip. (machines with 14 pin
amphenols pin C to pin D). If the
2. If a burnback kit is installed,
arc voltage is not present at the
remove and install the jumper
output terminals, the power
plug. If the problem is solved,
source is faulty. If the arc voltthe burnback kit is faulty.
age IS present, the problem is in
the wire feeder or control cable.
3. Check the #2 and #4 leads in the
LN-8 wiring harness for loose or
3. Check the continuity of leads #2
faulty connections. See wiring
and #4 through the control cable.
Replace if “open”.
diagram.
4. The welding gun may be faulty.
Check or replace.
The wire continues to feed with the
gun trigger open, and the wire is
electrically “hot”. The interlock
switch is in the “off” position.

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F-5

Observe all Safety Guidelines detailed throughout this manual

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F-5

1. Disconnect the gun trigger cable. 1. The 1CR relay may be stuck
closed. Perform the 1CR Relay
If the problem is solved, the gun
Test.
trigger or cable is faulty. Repair
or replace.
2. Check the relay board. Replace
if faulty.

With the interlock switch (S2) in the 1. Check leads #529 and #528 for
loose or faulty connections
“ON” postion, the wire feed stops
between the 2CR reed switch
when the gun trigger is released.
and the control board and motor
thermal circuit breaker. See
wiring diagram.

1. The 2CR reed switch may be
faulty. Check to see if it closes
when welding.
2. Check the interlock switch (S2)
for proper operation.
3. Check the continuity (zero ohms)
of leads #523 and #536 between
the interlock switch (S2) and the
relay board. See wiring diagram.

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4. The relay board may be faulty.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.

LN-8

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F-6

TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

Return to Master TOC

RECOMMENDED
COURSE OF ACTION

FUNCTION PROBLEMS (Continued)
The circuit breaker (5 amp)
repeatedly trips when the gun trigger is activated.

1. Check or replace the gun trigger 1. Perform the Trigger
and leads. Make sure the trigger
Transformer Test.
leads are not shorted to the electrode or work cables.
2. Perform the Drive Motor Test.
2. Disconnect any accessory that
3. Remove the molex plug from the
may be connected to terminals
relay board. If the circuit breaker
#7 and #32A. See wiring diacontinues to trip, the control
gram. If the problem is resolved,
board may be faulty. If the cirthe accessory may be faulty.
cuit breaker does not trip, the
relay board may be faulty.

The circuit breaker (5 amp) trips
when power is applied to the LN-8.
Gun trigger is NOT activated.

1. Disconnect any kits or acces1. Check the wiring harness leads
sories that may be incorporated
#32, #32A, #31, and #531 for
in the LN-8. Be sure to install
shorts or grounds. See wiring
any necessary jumper plugs. If
diagram.
problem is resolved the fault may
be in the disconnected kit.
2. Perform the Trigger
Transformer Test.
3. Remove the molex plug from the
relay board. If the circuit breaker
continues to trip, the control
board may be faulty. If the circuit breaker does not trip, the
relay board may be faulty.
4. Perform the Drive Motor Test.

The 1/2 amp fuse on the relay
board repeatedly fails.

1. Check to make sure the correct
input voltage (115VAC) is being
applied to the LN-8.

1. Perform the Drive Motor Test.
2. Perform the Trigger
Transformer Test.

2. Very rapid and repetitive gun
triggering can possibly cause the 2. The relay board may be faulty.
field fuse to fail.
The drive motor thermostat “opens” 1. Check for mechanical restricwhile welding.
tions in the wire feeding path.
This condition could cause the
motor to overheat.

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F-6

1. Perform the Drive Motor Test.

2. The electrode may be rusty or
dirty. Clean or replace.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.

LN-8

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F-7

TROUBLESHOOTING AND REPAIR

F-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FUNCTION PROBLEMS (Continued)
The wire feed speed cannot be
controlled. The motor runs and
feeds wire but the speed cannot
be changed regardless of control
setting.

1. If the LN-8 is being used for sub- 1. Check for loose connections
between the speed control, the
merged arc welding with the varicontrol board, and the variable
able voltage board switch in the
voltage board. See wiring
VV position, change it to the CV
diagram.
position. If proper motor speed
control returns, the variable volt2. Check the speed control rheostat
age board may be faulty.
for proper operation. Normal
resistance is 5000 ohms.
3. Perform the Drive Motor Test.
4. The control board may be faulty.

The wire feed “coasts” when the
gun trigger is released.

1. Make sure the gun trigger is not
“sticking”.

1. Perform the 1CR Relay Test.

The wire feeds normally and welds
but the solenoid is not operating.

1. Check or replace the solenoid.

1. With the gun trigger activated,
check for the presence of
115VAC at terminals 32A and 7.
If the proper voltage is present,
the solenoid may be faulty. If the
correct voltage (115VAC) is NOT
present, the relay board may be
faulty.

When the gun trigger is activated
1. Check wire feed direction switch 1. The 1CR relay may be faulty.
Check or replace.
the wire “backs up” instead of feedfor proper direction and operation.
ing forward.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.

LN-8

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F-8

TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

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RECOMMENDED
COURSE OF ACTION

FEEDING PROBLEMS
When the gun trigger is activated,
the drive rolls turn but the wire will
not feed or wire feeding is rough.

1. Check or replace the gun cable.
It may be kinked, clogged or
twisted.
2. Make certain the drive rolls and
guide tubes are correct for the
wire being used.

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F-8

1. If conditions are extremely dirty,
install a wiper on the wire before
it enters the guide tube. Use a
piece of cloth saturated with
“Pyroil B”.

3. Check or replace the gun contact
tip.
4. The electrode wire may be rusty
or dirty. Replace if necessary.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.

LN-8

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F-9

TROUBLESHOOTING AND REPAIR
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

The welding arc is variable or
“hunting”.

1. Make sure the welding parameters are correct for the welding
procedure being used.

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3. The gun cable may be faulty.
Check or replace.

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1. Put the power source in
“Machine Control” and check if
the welding performance
improves. If the problem is
resolved, check or replace the
control cable and/or check the
output control in the LN-8.
2. Perform the Drive Motor Test.

4. The gun contact tip may be
worn. Check or replace.
5. The welding power supply may
be faulty. Check or replace.
Poor arc striking with sticking or
“blast offs”. The weld bead may
also be ropey and display weld
porosity.

1. Make sure the welding parameters and techniques are correct
for the welding procedure being
used.
2. Check the welding cables for
loose or faulty connections.

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RECOMMENDED
COURSE OF ACTION

WELDING PROBLEMS

2. Check the welding cables for
loose or faulty connections.

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F-9

1. Put the power source in
“Machine Control” and check if
welding performance improves.
If the problem is resolved, check
or replace the control cable
and/or check the output control
in the LN-8.

3. The gun cable may be faulty.
Check or replace.
4. The gun contact tip may be
worn. Check or replace.
5. The welding power source may
be faulty. Check or replace.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.

LN-8

F-10

TROUBLESHOOTING AND REPAIR
LN-8 ELECTRICAL SEQUENCE OF OPERATION

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F-10

FIGURE F.1 – LN-8 ELECTRICAL SEQUENCE OF OPERATION
TURN ON POWER SOURCE

PRESS GUN TRIGGER

CLOSES 524-528

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ENERGIZES 1 CR

ENERGIZES POWER
SOURCE PILOT RELAY
ENERGIZES
POWER SOURCE
CONTACTOR

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ELECTRODE NOW
"HOT" TO GROUND
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OPENS 682-683
CLOSES 683-32A CIRCUIT

CLOSES 2-4 CIRCUIT

CLOSES 531-7

ENERGIZES
CONTROL CIRCUIT
(AND AUX. EQUIPMENT IF
CONNECTED TO 7-32A)

WIRE FEEDS DOWN

ARC STARTS

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ENERGIZES 2 CR
(REED SWITCH)
INTERLOCKS 1 CR IF
INTERLOCK SWITCH
IS CLOSED

MOTOR ACCELERATES
TO WELDING SPEED

WELDING

LN-8

REVERSES WIRE
FEED MOTOR
FIELD

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F-11

FIGURE F.1 – LN-8 ELECTRICAL SEQUENCE OF OPERATION (continued)
WELDING

RELEASE
GUN TRIGGER

BREAK
WELDING ARC

DE-ENERGIZES 1 CR

OPENS 2-4 CIRCUIT
DE-ENERGIZES
POWER SOURCE
PILOT RELAY

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DE-ENERGIZES
2 CR
REED SWITCH

OPENS INTERLOCK
ON 1 CR (NOTE 2)

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OPENS 2-8 (NOTE 1)

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F-11

TROUBLESHOOTING AND REPAIR

DE-ENERGIZES
POWER SOURCE
CONTACTOR

OPENS 531-7

OPENS 683-32A CIRCUIT
CLOSES 682-683

DISCONNECTS MOTOR ARMATURE
AND CONTROL CIRCUIT FROM
INPUT AC LINE - (DE-ENERGIZES
AUX. EQUIPMENT IF CONNECTED)

REVERSES
MOTOR FIELD

DYNAMIC BRAKE
CURRENT FLOWS
THROUGH FREE
WHEELING DIODE (D-7 ON
CONTROL BOARD)

ELECTRODE IS
COLD TO WORK

3CR (NOTE 3)
REED SWITCH
MOMENTARILY
CLOSES

DISCHARGES SLOW
ACCELERATION
CAPACITOR (C3 ON
CONTROL BOARD)

MOTOR STOPS

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RESETS SLOW
ACCELERATION
CIRCUIT

UNIT READY
FOR NEXT WELD

NOTE 1: When interlock is open.
NOTE 2: When interlock is closed.
NOTE 3: 3 CR is not used on units with code no. 7926 and up.
LN-8

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F-12

TROUBLESHOOTING AND REPAIR
TRIGGER TRANSFORMER TEST

WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION
This test will aid the technician in determining if the Trigger Transformer is functioning
properly.
This procedure takes approximately 8 minutes to perform.

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MATERIALS NEEDED
115 VAC power supply
5/16 in. nutdriver
Volt-Ohmmeter (Multimeter)

LN-8

F-12

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F-13

TROUBLESHOOTING AND REPAIR
TRIGGER TRANSFORMER TEST (continued)
FIGURE F.2 – TRIGGER TRANSFORMER TEST POINTS

6 5 4
RED
3 2 1
BLACK BLACK

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RELAY
BOARD

TEST PROCEDURE
1. Remove input power to the LN-8.
2. Using the 5/16 in. nutdriver,
remove the screws holding the left
side cover assembly.
3. Disconnect the Molex plug from
the under-side of the relay board.
See Figure F.2.

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4. Apply power (115VAC) to the
black primary transformer leads,
pins 2 and 3.

LN-8

5. Using the voltmeter, check for
approximately 24VAC at the red
secondary leads, pins 1 and 4.
6. If 115VAC is applied to the black
primary leads (2 and 3) and the
secondary voltage (red leads 1
and 4) is missing or low, the trigger transformer may be faulty.
Replace.
7. Reconnect the Molex plug to the
underside of the relay board.
8. Install the screws that secure the
left side cover assembly.

F-13

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F-14

TROUBLESHOOTING AND REPAIR
INTERNAL VOLTAGE TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

Return to Master TOC

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If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION
This test will aid the technician in determining if the correct voltages are present in the LN-8.
This procedure takes approximately 20 minutes to perform.

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MATERIALS NEEDED
5/16 in. nutdriver
Volt-Ohmmeter
Wiring diagram

LN-8

F-14

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F-15

TROUBLESHOOTING AND REPAIR
INTERNAL VOLTAGE TEST (continued)
FIGURE F.3 – VOLTAGE TEST POINTS
INPUT
RECEPTACLE

32A

B
C

A
H

115 VAC
APPLIED

INPUT
CIRCUIT
BREAKER

CONTROL
BOARD
CONNECTOR
PLUG

PIN #12
(32A)

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PIN #2
(7)

CONTROL
BOARD
541
539

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PIN #1
(32A)

PIN #4
(531)

627

626
A
31

2 OHM
RESISTOR (R4)

531

GUN TRIGGER
RECEPTACLE

32A

RELAY
BOARD

4. Apply 115VAC to the input
receptacle at pins C and D.

TEST DESCRIPTION

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1. Remove input power to the LN-8.
2. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.

5. Using the voltmeter, carefully
test the voltages per Table F.1
at the test points shown in
Figure F.3.
6. When testing is complete,
install the screws that secure
the left side cover assembly.

3. Lift the left side cover.

LN-8

525
(A)

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F-16

TROUBLESHOOTING AND REPAIR
INTERNAL VOLTAGE TEST (continued)
TABLE F.1 – VOLTAGE TEST POINTS

LEAD NO.

ACCEPTABLE
VOLTAGE
READING

Input voltage before the
circuit breaker and 2
ohm resistor (R4).

#31 and #32

103 to 126VAC

Input Circuit Breaker
and
Resistor R4

Input voltage after the
circuit breaker.

#31 and #32A

103 to 126VAC

Input Circuit Breaker
and
Resistor R4

Input voltage after the
circuit breaker and 2
ohm resistor (R4).

#531 and #32A

103 to 126VAC

Gun trigger receptacle
pins A and C

Check voltage across
gun trigger - trigger open.

#524 (pin A) and
#528 (pin C)

34 to 42VDC

Terminals #7 and #32A
located on relay board

Auxiliary terminals
(gas solenoid)
Note: Gun trigger must
be activated.

#7 and #32A

103 to 126VAC

Terminals #626 and
#627 located on relay
board

Drive motor field
voltage.

#626 and #627

102 to 125VDC

Terminals #539 and
#541 located on control
board

Drive motor armature
voltage.
Note: Gun trigger must
be activated and
armature voltage will
be dependent upon wire
speed setting.

#539 and #541

4VDC (min) 90VDC (max).

Control board
connector plug

Check that 115VAC is
being applied to control
board when gun trigger
is activated.

#32A (pin 12) and
#7 (pin 2)

103 to 126VAC

Relay board connector
plug

Check that 115VAC is
being applied to the
control board.

#32A (pin 1) and
#531 (pin 4)

103 to 126VAC

CHECKPOINT
LOCATIONS

TEST
DESCRIPTION

Input Circuit Breaker
and
Resistor R4

LN-8

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F-17

TROUBLESHOOTING AND REPAIR
1CR RELAY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

Return to Master TOC

Return to Section TOC

_____________________________________________________________

TEST DESCRIPTION
This test will determine if the control relay is functioning properly by measuring the resistance
across the contacts when the relay is energized and de-energized.
This procedure takes approximately 15 minutes to perform.

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MATERIALS NEEDED
Volt-Ohmmeter
24VDC power supply
5/16 in. nutdriver

LN-8

F-17

TROUBLESHOOTING AND REPAIR
1CR RELAY TEST (continued)

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F-18

FIGURE F.4 – 1CR RELAY TEST POINTS

NORMALLY CLOSED
NORMALLY OPEN
COMMON

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+
24VDC

1CR RELAY

RETAINING
CLIP

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MOLEX
PLUG
RELAY
BOARD

TEST PROCEDURE
1. Remove input power to the LN-8.
2. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.

Note: The Molex plug located on the
relay board may have to be removed to
gain access to the 1CR relay.
5. Connect the 24VDC supply to terminals A- and B+ on the 1CR
relay. Do not energize the power
supply at this time.

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3. Lift the left side cover.
4. Locate the 1CR relay. Slide the
retaining clip off the relay and
carefully remove the relay from the
relay board. See Figure F.4.

LN-8

6. Connect the ohmmeter across the
first set of terminals shown in
Table F.2.

F-18

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F-19

TROUBLESHOOTING AND REPAIR
1CR RELAY TEST (continued)
TABLE F.2 – RELAY TEST TERMINAL CONNECTIONS

Terminals
7-1
7-4
8-2
8-5
9-3
9-6

Terminals
A&B
Energized
Open
Closed
Open
Closed
Open
Closed

7. Measure the resistance across the
contacts. A resistance of less than
one ohm indicates that the contacts are closed. An infinite resistance indicates that the contacts
are open. Energize the 24VDC
power supply and measure the
resistance again. Compare to the
conditions given in Table F.2. If the
readings do not match the table,
the relay is faulty and should be
replaced.

LN-8

Terminals
A&B
De-energized
Closed
Open
Closed
Open
Closed
Open

8. Repeat the above procedure for all
of the contacts.
9. Re-install relay into the relay
board.
10. Install the screws that secure the
left side cover assembly.

F-19

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F-20

TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

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_____________________________________________________________

TEST DESCRIPTION
This test will help determine if the drive motor is functioning correctly.
This procedure takes approximately 20 minutes to perform.

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MATERIALS NEEDED
5/16 in. nutdriver
Volt-Ohmmeter
Variable DC voltage supply 0 to 90VDC
Isolated DC voltage supply 120VDC

LN-8

F-20

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F-21

TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST (continued)
FIGURE F.5 – DRIVE MOTOR TEST POINTS

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#541
#539

#626
#627

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TEST PROCEDURE
1. Remove input power to LN-8.
2. Remove the electrode wire or disengage drive rolls.

3. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
4. Lift the left side cover.
5. Locate leads #539 and #541 at the
control board. See Figure F.5.

LN-8

F-21

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TROUBLESHOOTING AND REPAIR
DRIVE MOTOR TEST (continued)
FIGURE F.6 – GUN TERMINAL JUMPER LOCATIONS

LN-8 RELAY

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F-22

1CR
RELAY

627
626
7

529

32A

7. If a variable voltage board is
installed in the LN-8, make certain the mode switch is in the CV
position.
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6. Locate leads #626 and #627 at the
relay board.

8. Apply 115VAC to the input receptacle at pins C and D.
9. With the gun trigger activated or
the gun trigger terminals jumpered
together, (see wiring diagram),
check the motor armature volts at
leads #541 (+) and #539 (-).
Normal is 5 to 95VDC dependent
upon the setting of the wire feed
speed control.

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10. With the LN-8 at idle (gun trigger
NOT activated) check the motor
field voltage at lead #626 and

LN-8

524(A) 525(A)

#627. Normal is 115VDC. When
the gun trigger is activated or the
gun terminals jumpered together,
Figure F.6, the field voltage polarity should reverse from the idle
state. Normal is 115VDC and is
independent of motor speed.
Note: The wire feed direction switch
(S3) must be in the forward, or “welding” position.
11. If the above voltages are present
and motor does not operate, the
motor, motor brushes, or the gear
box may be faulty. If the armature
voltage is not correct (leads #539
and #541), the control board may
be faulty. If the field voltage is not
correct (leads #626 and #627), the
1CR relay or relay board may be
faulty.

F-22

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F-23

DRIVE MOTOR TEST (continued)
To further check the drive motor:
12. Remove input power (115VAC)
from the LN-8.

3. Apply field voltage first (leads #626
and #627) to the motor. Then
slowly apply the armature voltage
at leads #539 and #541.

13. Locate and remove leads #539
and #541 from the control board,
see Figure F.5.

4. The motor should run and the
speed should vary with changes to
the armature voltage.

14. Locate and remove leads #626
and #627 from the relay board.

5. If the motor does NOT run and
change speed correctly, the motor
or gear box may be faulty.

15. Using the ohmmeter, measure the
resistances per Table F.3.
16. If the motor resistance test is
good, proceed to the Motor
Applied Voltage Test.

MOTOR APPLIED
VOLTAGE TEST

1. Replace motor leads.

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2. Carefully connect the variable 0 to
120VDC supply (supply turned off)
to motor leads #539 and #541.

2. Install the screws that secure the
left side cover assembly.
3. If disengaged, engage the drive
rolls.
4. If removed, feed the electrode
back into the wire drive unit.

TABLE F.3 – DRIVE MOTOR TEST POINTS
TEST POINTS

RESISTANCE

DC VOLTAGE

Lead #539 to #541
Armature

3 to 5 ohms

0 to 90VDC

Lead #626 to #627
Field Winding

750 to 950 ohms

90 to 120VDC

All leads to
motor shell

500,000 ohms
min.

N/A

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6. To stop the motor, remove the
armature voltage first, leads #539
and #541.

AFTER TESTING

1. Carefully connect the isolated
120VDC supply (supply turned off)
to motor leads #626 and #627, see
Figure F.5.

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F-23

TROUBLESHOOTING AND REPAIR

LN-8

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F-24

TROUBLESHOOTING AND REPAIR
POTENTIOMETER REPLACEMENT

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_____________________________________________________________

MATERIALS NEEDED
5/16 in. nutdriver
1/2 in. wrench
5/64 in. Allen wrench
Small slothead screwdriver
Soldering iron and solder

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This procedure takes approximately 10 minutes to perform.

LN-8

F-24

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F-25

TROUBLESHOOTING AND REPAIR
POTENTIOMETER REPLACEMENT (continued)
FIGURE F.7 – POTENTIOMETER REMOVAL
POTENTIOMETER

NUT
KNOB
INSULATION
LOCKWASHER

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SET
SCREW

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REPAIR PROCEDURE
1. Remove input power to the LN-8
2. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
3. Using a 5/64 in. Allen wrench or
slothead screwdriver, loosen the
setscrew on the potentiometer knob
and remove the knob from the
potentiometer. Refer to Figure F.7.

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4. Remove the nut and lockwasher
holding the potentiometer to the
left side cover assembly.
5. Remove the potentiometer and
insulation sheet from the inside of
the left side cover assembly.
6. Tag the three wires on the potentiometer so that they can be reattached in the same location from
LN-8

where they were removed.
Unsolder the three wires from the
potentiometer.
7. Solder the three wires to the new
potentiometer on the corresponding terminals from where they were
removed.
8. Place the new potentiometer and
insulation sheet through the cover
assembly from the inside. Ensure
that the index pin in the potentiometer fits in the locating hole on
the cover assembly. Install the
lockwasher and nut on the potentiometer. Tighten the nut until it is
snug.
9. Install the knob onto the potentiometer so the set screw aligns
with the flat on the potentiometer.
Tighten the set screw.
10. Install the screws that secure the
left side cover assembly.

F-25

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F-26

TROUBLESHOOTING AND REPAIR
CIRCUIT BREAKER REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

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_____________________________________________________________

MATERIALS NEEDED
5/16 in. nutdriver
9/16 in. wrench

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This procedure takes approximately 6 minutes to perform.

LN-8

F-26

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F-27

CIRCUIT BREAKER REPLACEMENT (continued)
FIGURE F.8 – CIRCUIT BREAKER AND GROUND LEAD PROTECTOR REPLACEMENT
SCREW

CIRCUIT
BREAKER

RETAINING
NUT

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GROUND LEAD
PROTECTOR SWITCH

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F-27

TROUBLESHOOTING AND REPAIR

SWITCH
MOUNT

FLATWASHER
LOCKWASHER

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NUT

on the wire feeder. Remove the
circuit breaker from the wire
feeder.

REPAIR PROCEDURE

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1. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
2. Tag and remove the two connectors from the back of the circuit
breaker. Refer to Figure F.8.
3. Using the 9/16 in. wrench, remove
the retaining nut that secures the
circuit breaker to the center panel
LN-8

4. Install the new circuit breaker
through the panel of the control
box. Secure the circuit breaker
with the retaining nut.
5. Install the connectors onto the
back of the circuit breaker at the
positions they were removed from.
6. Install the screws that secure the
left side cover assembly.

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F-28

TROUBLESHOOTING AND REPAIR
GROUND LEAD PROTECTOR PUSH BUTTON
SWITCH REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (800) 833-9353 (WELD).

_____________________________________________________________

MATERIALS NEEDED
5/16 in. nutdriver
3/32 in. wrench
Jewelers’ flat blade screwdriver
Soldering iron and solder

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This procedure takes approximately 10 minutes to perform.

LN-8

F-28

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F-29

TROUBLESHOOTING AND REPAIR
GROUND LEAD PROTECTOR PUSH BUTTON
SWITCH REPLACEMENT (continued)
REPAIR PROCEDURE
1. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.

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2. Using the 3/32 in. wrench and jewelers’ flat blade screwdriver,
remove the ground lead protector
switch from the switch mount.
Refer to Figure F.8.

3. Remove insulation and unsolder
the two leads from the ground lead
protector switch.
4. Solder the two leads onto the
new switch and reinsulate the
connections.
5. Place the switch onto the switch
mount and install the screws, flat
washers, lockwashers and nuts
that secure the switch into place.
6. Install the screws that secure the
left side cover assembly.

LN-8

F-29

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F-30

TROUBLESHOOTING AND REPAIR
TRIGGER TRANSFORMER REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

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_____________________________________________________________

MATERIALS NEEDED
5/16 in. nutdriver
Flat blade screwdriver
Needlenose pliers

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This procedure takes approximately 12 minutes to perform.

LN-8

F-30

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F-31

TROUBLESHOOTING AND REPAIR
TRIGGER TRANSFORMER REPLACEMENT (continued)
FIGURE F.9 – TRIGGER TRANSFORMER REMOVAL

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ROUNDHEAD
SCREW
RELAY
PC BOARD

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INSULATION
SHEET
TRIGGER
TRANSFORMER
NUT

1. Using the 5/16 in. nutdriver
remove the screws from the left
side cover assembly.

5. Place the insulation sheet and new
trigger transformer into the case
and install the screws and nuts
that secure the transformer in
place.

2. Remove the Relay PC board as
described in the PC Board
Replacement procedure.

6. Install the Relay PC board as
described in the PC Board
Replacement procedure.

3. Disconnect the Molex plug for the
trigger transformer from the bottom
of the relay board. Refer to Figure
F.9.

7. Attach the trigger transformer
Molex plug to the bottom of the
relay board.

REPAIR PROCEDURE

4. Using a flat blade screwdriver and
needlenose pliers, remove the trigger transformer and insulation
sheet from the case.
LN-8

8. Install the screws that secure the
left side cover assembly.

F-31

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F-32

TROUBLESHOOTING AND REPAIR
PC BOARD REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

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_____________________________________________________________

MATERIALS NEEDED
5/16 in. nutdriver
Phillips screwdriver

The Variable Voltage board takes approximately 5 minutes to replace.

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The Relay board takes approximately 5 minutes to replace.
The Control board takes approximately 5 minutes to replace.

LN-8

F-32

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F-33

TROUBLESHOOTING AND REPAIR
PC BOARD REPLACEMENT (continued)
FIGURE F.10 – PC BOARD LOCATIONS

VARIABLE
VOLTAGE
PC BOARD
RELAY
PC BOARD

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CONTROL
PC BOARD

REPAIR PROCEDURE
1. Observe the static precautions
detailed in the PC Board
Troubleshooting Procedures at
the beginning of this section.

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2. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.
CAUTION: Label all wires and connectors prior to removal. All wires and connectors must be reconnected to the
same terminals from where they were
removed. Improper connection may
lead to component damage or machine
malfunction.

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VARIABLE VOLTAGE BOARD
REMOVAL AND REPLACEMENT
1. Disconnect all plugs and connectors that can be reached without
removing the variable voltage PC
board. Refer to Figure F.10.

LN-8

2. Using a Phillips screwdriver,
remove the screws that secure the
variable voltage PC board to the
case.
NOTE: The screws that secure the
Variable Voltage PC board are on the
wire drive assembly side of the unit.
3. Carefully move the PC board away
from the case, checking to ensure
that all plugs and connectors have
been removed. Disconnect any
connectors that have been missed
or that could not be reached while
the PC board was installed.
4. Place the new PC board into the
case and install the mounting
screws.
5. Connect all plugs and connectors
to the PC board in the same location they were removed from.
6. Install the screws that secure the
left side cover assembly.

F-33

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F-34

TROUBLESHOOTING AND REPAIR
RELAY BOARD REMOVAL AND
REPLACEMENT
1. If the Relay PC board is being
replaced, remove the 1CR Relay
from the PC board.
2. Disconnect all plugs and connectors.
3. Remove mounting screws.

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4. Place the new PC board into the
case and install the mounting
screws.
5. Install the 1CR Relay into the PC
board.
CAUTION: Do not use excessive force
when installing the 1CR Relay.
Excessive force can damage the Relay
PC board. If the relay does not fit properly, remove it and try again.
6. Connect all plugs and connectors
to the PC board in the same location they were removed from.

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7. Install the screws that secure the
left side cover assembly.

LN-8

CONTROL PC BOARD
REMOVAL AND
REPLACEMENT
1. Disconnect all plugs and connectors from the Control PC board.
2. Using a Phillips screwdriver,
remove the screws that secure the
Control PC board to the case.
3. Carefully move the Control Board
away from the case. Check to
ensure that all plugs and connectors have been disconnected.
4. Place the new PC board into the
case and install the mounting
screws.
5. Connect all plugs and connectors
to the PC board in the same location they were removed from.
6. Install the screws that secure the
left side cover assembly.

F-34

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F-35

TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

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_____________________________________________________________

MATERIALS NEEDED

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Offset flat blade screwdriver
Flat blade screwdriver
Phillips screwdriver
7/16 in. wrench
1/2 in. wrench
11/32 in. wrench
Insulating tape
This procedure takes approximately 40 minutes to perform.

LN-8

F-35

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F-36

TROUBLESHOOTING AND REPAIR

WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
FIGURE F.11 – DRIVE MOTOR ELECTRICAL CONNECTIONS

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YELLOW
(#525)

BLACK
(#541)
BLUE
(#539)
WHITE
(#627)

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RED
(#626)

BLUE (TWO)
(#528)

GREEN
(GROUND)
YELLOW
(#528)

REPAIR PROCEDURE

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1. Using the 5/16 in. nutdriver,
remove the screws from the left
side cover assembly.

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F-36

2. Disconnect drive motor leads #539
(blue) and #541 (black) from the
back of the Control PC board.
Refer to Figure F.11.
3. Disconnect drive motor leads #626
(red) and #627 (white) from the
side of the Relay PC board.

LN-8

4. Using a Phillips screwdriver, disconnect the drive motor ground
lead (green) from the case.
5. Separate ground lead protection
wire #525 (yellow) at the in-line
connector.
6. Remove the insulating tape from
wire #528 (yellow) and disconnect
it from the reed switch wire and
gun receptacle wire (#528, and
both blue leads) using a 11/32 in.
wrench and a Phillips screwdriver.
See the wiring diagram.

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F-37

TROUBLESHOOTING AND REPAIR

F-37

WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
FIGURE F.12 – REED SWITCH REMOVAL AND SHUNT ELECTRICAL CONNECTIONS
HEX HEAD
SCREWS

REED
SWITCH
BRACKET

SHUNT
#568

#567

7. Disconnect two leads #567 (blue),
and lead #568 (blue) from the
shunt using the 11/32 in. wrench.
See Figure F.12. Note the lead
placement on the shunt for
reassembly.
8. Using a 7/16 in. wrench, loosen
the two hex head screws that
secure the reed switch bracket to

LN-8

the front of the wire drive assembly. Slide the bracket off the front
of the wire drive assembly.
9. Using an offset flat blade screwdriver, remove the two mounting
screws below the shunt and the
one mounting screw below the
wire drive motor. Remove the wire
drive assembly through the wire
drive side of the case.

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F-38

TROUBLESHOOTING AND REPAIR

WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
FIGURE F.13 – WIRE DRIVE ASSEMBLY REMOVAL

BRUSH
WIRE
DRIVE
MOTOR

BRUSH
SCREW

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GEARBOX

INSULATION
SHEET

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MOUNTING
PLATE

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F-38

10. Using a 1/2 in. wrench, remove the
four hex head screws, lockwashers and flat washers that hold the
mounting plate to the gear box
assembly, and remove the mounting plate and insulation sheet.
Refer to Figure F.13.
11. Using a flat blade screwdriver,
remove the three screws, lockwashers, flat washers and spacers

LN-8

that secure the drive motor to the
gearbox assembly, and remove
the drive motor.
12. For further disassembly of the wire
drive assembly, refer to Figure
F.13.
13. Secure the drive motor to the gearbox assembly using three screws,
lockwashers, flat washers, and
spacers.

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F-39

TROUBLESHOOTING AND REPAIR

WIRE DRIVE ASSEMBLY AND COMPONENT REPLACEMENT (continued)
14. Install the gearbox assembly onto
the insulation sheet and mounting
plate using four hex head screws,
lockwashers and flat washers.
Ensure that the edge of the mounting plate that has the single
mounting hole is under the drive
motor.

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15. Place the wire drive assembly into
the case. Secure the wire drive
assembly using three round head
screws and lockwashers.

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F-39

16. Position the reed switch bracket
onto the front of the wire drive
assembly and tighten the two hex
head screws that secure it in
place. Refer to Figure F.12.
17. Connect the two #567 (blue) leads
and the #568 (blue) lead to the
shunt. Note lead placement. Refer
to Figure F.13.

LN-8

18. Connect the #528 wire (yellow)
from the drive motor to the reed
switch wire and gun receptacle
wire (both #528 blue) using the
round head screw and nut. Wrap
the connection in insulating tape.
Refer to Figure F.11.
19. Connect the drive motor wire #525
(yellow) to the ground lead protection wire at the in-line connector.
20. Connect the drive motor ground
lead (green) to the case.
21. Connect the drive motor leads
#539 (blue) and #541 (black) to
the back of the Control PC board.
22. Connect drive motor leads #626
(red) and #627 (white) to the side
of the Relay PC board.
23. Install the screws that secure the
left side cover assembly.

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F-40

TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
If a failed test indicates that any
mechanical part that could affect the
machine’s electrical characteristics
must be replaced or if any electrical
components are repaired or replaced,
the machine must be retested and meet
the following standards.

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Wire Feed Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 to 600 IPM
Gas Solenoid (If Used) . . . . . . . . . . . . .

Must function when gun trigger is activated.

1CR Relay . . . . . . . . . . . . . . . . . . . . . .

Must function when gun trigger is activated.

2CR Reed Switch . . . . . . . . . . . . . . . . . Must close when welding current is present.

LN-8

F-40

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G-1

ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-2
Connection Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-3
Operating Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-4
Control Board (L5767) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-5
Variable Voltage Board (L5039) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-6
Control Board (L5767) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-7
Variable Voltage Board (L5039) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-8

G-1

Wiring Diagram

LN-8N, -8NE, -8S, AND -8SE WIRING DIAGRAM
JUMPER CONNECTOR IS REMOVED AND CONNECTOR
"A" PLUGGED INTO OPTIONAL VARIABLE VOLTAGE

JUMPER CONNECTOR IS REMOVED

502 4 504 531 32A

AND CONNECTOR "B" PLUGGED

BURNBACK P.C. BOARD

POWER SOURCE BOARD.

(OPTIONAL)

N.B.

INTO OPTIONAL BURNBACK

P.C. BOARD.

5
CONTROL

Return to Master TOC

Return to Section TOC

541

*J 1

THERMAL CIRCUIT
R

626

BREAKER

539
B

541
WIRE

528

FEED

525

32A

543

32A

637

636

635

631

632

634

627

632

CONNECTOR "A"

VARIABLE VOLTAGE
P.C. BOARD

636 637 567

INTERLOCK SWITCH

DIRECTION

627

OF WIRE

536

682

683

SWITCH

631

POWER SOURCE
OUTPUT
RHEOSTAT

32A
32

5K OHMS

634

(OPTIONAL)

5 AMP CIRCUIT BREAKER

523

OFF

10K OHMS

G
BEAD PINS ON

GROUNDING

BOTTOM OF BOARD

PROTECTOR

504

525

WORK TO POWER SOURCE

525A

Return to Master TOC

635

539

WIRE FEED

LEAD

GND

10 4

W = WHITE

G = GREEN

U = BLUE

R = RED
NOTES:

RELAY
P.C. BOARD

32A

526

531A

32A

522

1 / 2A M P 1 2 5 V .
OR 250V. SLOW
BLOW FUSE
7

1CR

529

525A

LOW VOLTAGE

TRIGGER
TRANSFORMER

B
R

6
5
524

626
524

528

B
QUICK CONNECT TERMINALS 7 & 32A

TO CONNECT AUXILIARY EQUIPMENT

.1 OHMS

GND 541
21

531

CASE
GROUNDING
SCREW

CONNECTOR CAVITY NUMBER
CONNECTIONS AS VIEWED FROM
BACK OF RHEOSTATS WHEN
COVER IS UP

N.A. RESISTOR USED ON CODES 9090 AND BELOW. FOR CODES ABOVE 9090
THE GROUNDING LEAD PROTECTOR CONNECTS DIRECTLY TO THE CASE
GROUNDING SCREW.
N.B. THE VARIABLE VOLTAGE BOARD IS FACTORY INSTALLED IN CV-VV MODELS
AND DOES NOT INCLUDE JUMPER CONNECTOR.

528

567
568

OPTIONAL METER
3

529

115 V.A.C., .25 AMP RATING
543

2CR REED SWITCH
568

BOLTED
CONNECTION

567
GUN CABLE

KIT RECEPTACLE
METER SHUNT

*
B = BLACK

11 1 8

683
536
627
682

N.A.

SCREW

LEAD COLOR CODING

32A
531
523 7
502

627

CASE
GROUNDING

4CR

GND

2 OHMS

Return to Master TOC

FEED
W

637

567

SPEED

541

636

RHEOSTAT

MOTOR

Return to Section TOC

635

BOARD

CONNECTOR "B"

P.C.

502 4 504 53132A

Return to Section TOC

G-2

ELECTRICAL DIAGRAMS

ELECTRODE TO POWER SOURCE

Return to Master TOC

Return to Section TOC

G-2

WORK

RELAY AND
CONTROL BOARD

TO CONTACTOR CIRCUIT
115 VAC
TO POWER SOURCE WORK
TERMINAL

METER KIT
RECEPTACLE

BURNBACK

1 4

1 4 7 10

3 6

AND VARIABLE

2 5 8 11

2 5

VOLTAGE BOARD

3 6 9 12

1 4

CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF BOARD)

PIN SIDE OF
CONNECTOR

ELECTRICAL SYMBOLS PER E1537

2-1-2002M
M14679

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
LN-8

Ch’ge. Sht. No.
THIS SHEET CONTAINS PROPRIETARY INFORMATIONUNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E2056
OWNED BY THE LINCOLN ELECTRIC CO. AND IS
3-31-83N
ON 2 PLACE DECIMALS IS .02
NOT TO BE REPRODUCED, DISCLOSED OR USED
11-14-86G
ON 3 PLACE DECIMALS IS .002
WITHOUT THE EXPRESS PERMISSION OF
2-13-87G
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE t(" ") TO AGREE
THE LINCOLN ELECTRIC CO.
WITH PUBLISHED STANDARDS.

567

THE LINCOLN ELECTRIC CO. TYPE

EQUIP.

CLEVELAND, OHIO U.S.A.
SCALE

DR FI
NONE

DATE6-20-97

SUBJECT

CHK
REF.
SUP’S’D’G
3-4-83

568

567

543

539

634

567

CONNECTOR "A"

NO.

SHT.

543

637

MOTOR
GND

541

RECEPTACLE

METER KIT

WIRE FEED

626

528

541

32A

626

504

502

Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
ELECTRICAL SYMBOLS PER E1537

ACTUATED BY MOTOR TEMPERATURE

INTO OPTIONAL BURNBACK P.C. BOARD

JUMPER CONNECTOR IS REMOVED AND CONNECTOR "B" IS PLUGGED

ARM

TO POWER SOURCE WORK TERMINAL

627

525

636

32A

THERMAL CIRCUIT BREAKER

635

CONTROL

SPEED

WIRE FEED

32A

637
VARIABLE VOLTAGE P.C. BD. (OPTIONAL)

539

632

REV.

682

7
32A

1CR

4CR

BOLTED
CONNECTION

525

GND

5 AMP
BREAKER

CIRCUIT

531

32A 531

32A

502

504

JUMPER CONNECTOR

JUMPER CONNECTOR.

MODELS AND DOES NOT INCLUDE

FACTORY INSTALLED IN CV-VV

THE VARIABLE VOLTAGE BOARD IS

SOURCE BOARD.

OPTIONAL VARIABLE VOLTAGE POWER

CONNECTOR "A" PLUGGED INTO

JUMPER CONNECTOR IS REMOVED AND

.25 AMP RATING

AUXILIARY EQUIPMENT 115 V.A.C.

BOARD FOR CONNECTION OF

"B"

CONNECTOR

JUMPER

Return to Master TOC

Return to Section TOC

QUICK CONNECT TERMINALS ON

CASE GROUNDING
SCREW

THE GROUNDING LEAD
PROTECTOR CONNECTS
DIRECTLY TO THE CASE
GROUNDING SCREW.

RESISTOR USED ON CODES
9090 AND BELOW ONLY.
FOR CODES ABOVE 9090

32A

BURNBACK
P.C. BOARD (OPTIONAL)

TO OPERATE CONTACTOR

525A

LOW VOLTAGE
TRIGGER TRANSFORMER

P.C. BOARD

RELAY

627

SWITCH

GUN TRIGGER

528
524
2CR REED SWITCH

CONTROL P.C. BD.

631

FWD.

683

FEED SWITCH

OF WIRE

DIRECTION

627

531

524

OFF

SWITCH

GROUND LEAD PROTECTOR

POWER SOURCE
OUTPUT CONTROL

536

INTERLOCK

10K

523

115 V.A.C. (31 AND 32)

WORK

568

SHUNT

METER

531

525A

529

526

TO POWER SOURCE

Return to Master TOC

531A

Return to Master TOC

ELECTRODE TO POWER SOURCE

Return to Section TOC

32A

Return to Section TOC

WORK TO POWER SOURCE

NOTE:
522

M 14669

Return to Section TOC

G-3

ELECTRICAL DIAGRAMS
G-3

CONNECTION SCHEMATIC

LN-8N AND -8S

CONNECTION SCHEMATIC

14669

LN-8

OPERATING SCHEMATIC

R118

TP301

C301

R305
R308

R307

D303

D301

C303
C305

C101

R113

R301
C302

PT301

R310

C304

D304

Q301

D302

R304

C110
634

R110

L101

632

R121
R102

R119

R120

R128

QU301

D112

C102

D111

R112

D113

VOLTAGE

TO
POWER
SOURCE

C307

C103

C105

C106

PT101

R107

R129

QU101

ARC

631

R122
C104

C112
R106

D106

D105

531

CASE GROUNDING

D102

C111

FEED
FIELD

LN-8
SHUNT

DZ302

R101

Q102

F201

R109

R105

D107

TP101

MOTOR

R201

201

Q302
637

(R)
626

DZ301

C306

TO
GUN
CABLE

D110

C109

R108

R203

D109

567

R306

R103

R115

R114

D108

Q101
Q103

(U)

CV VV

R309

S304
PT301

R303

R302

C113
R116

635

B
R117

539

R111

DZ101

32A
7

SCR101 SCR102

(W)

R206

526

568

R125
D114

R123

C108

C107

D202
1CR

R202
R204
C201

C205

627

1CR

N.B.

R311

539

SCREW

VARIABLE VOLTAGE CONTROL CIRCUIT TO RIGHT OF THIS LINE. TO

Return to Master TOC

OPERATE LN-8 WHEN THIS CIRCUIT IS NOT INSTALLED IN UNIT,
RELAY CIRCUIT (BOARD #2)

CONTROL CIRCUIT (BOARD #1)
C101

1MFD

L101

5.6MH

C102

2MFD

Q101

2N4125

C103

39MFD ~10%

Q102

2N4123

C104

4.7MFD

Q103

2N5815

C105

.10MFD

QU101

2N6027

TP101

TRANSIENT PROTECTION

C106, C110,C111
C112, C113
C107, C108
C109

Return to Master TOC

Return to Section TOC

PT101

SCR

531

R124
D101

(B)

WIRE

COIL

DIRECTLY TO THE CASE GROUNDING SCREW.
R126

683
682

1CR
C202

GND

SCHEMATIC.

568

567

ABOVE 9090 THE GROUNDING LEAD PROTECTOR CONNECTS

R127

541

PT101

D204

504

D104

529

D205

525A
522
T1

GND LEAD
PROTECTOR

D201

524

1CR

2CR

C206

TO POWER
SOURCE TO
OPERATE
CONTACTOR
2

528
TH1

523

541 543

32A

536

C204

502

6
1

Return to Master TOC

Return to Section TOC

TP201

504

D103

BREAKERS

525

531
4

CIRCUIT

PROTECTOR
SWITCH

D203

5
4
2

OPTIONAL BURNBACK P.C. BOARD. SEE S15123 FOR OPERATING
GND

THERMAL

GND LEAD

N.A.
32A

N.A. JUMPER PLUG IS REMOVED AND CONNECTOR "B" IS PLUGGED INTO

METER KIT RECEPTACLE

N.B. RESISTOR USED ON CODES 9090 AND BELOW ONLY. FOR CODES

C203

77
5 AMP CIRCUIT
BREAKER
32A

R205

CASE
GROUNDING
SCREW

Return to Section TOC

G-4

ELECTRICAL DIAGRAMS

R20

Return to Master TOC

Return to Section TOC

G-4

.047MFD

SCR101 12A 400V
SCR102 12A 400V
PT101

.005MFD

1:1:1 PULSE TRANSFORMER

D101

1A.

R101

6.8K

R116

10K

D102

1A.

R102

2K TRIMMER

R117

22K

D103

1A.

R103

10K

R118

4.7K

D104

1A.

R105

4.7K

R119

27K

D105

16A.

R106

4.7K

R120

15K

D106

16A.

R107

R121

1.5K

D107

16A.

R108

33K

R122

10K

D108

1A.

R109

33K

R123

.25 7W

D109

1A.

R110

750

R124

1K TRIMMER

D110

1A.

R111

50K TRIMMER

R125

4.7K 4W

D111

1A.

R112

27K

R126

1K TRIMMER

D112

1A.

R113

39K

R127

150

D113

1A.

R114

10K

R128

D114

1A.

R115

68K

R129

15K

DZ101 20V.

NOTE:

.02 MFD

POINT "A" TO "B" IS JUMPERED.

C201

50MFD

C202

.02MFD

C203

50MFD

C301

2MFD

R301

6.8K

2 50W

C204

.005MFD

C302

.10MFD

R302

5.6K (2%)

5K 2W POT.

C205

50MFD

C303

.01MFD

R303

1K (2%)

R20

10K 2W POT.

C206

.005MFD

C304

.047MFD

R304

3.9K (2%)

110-24V TRANSFORMER

1CR

3PDT 24V.D.C.

C305

.01MFD

R305

3.3K

2CR

REED SWITCH (ACTUATED BY WELDING CURRENT)

D201

1A.

C306, C307

.02MFD

R306

4.7K

4CR

GROUNDING LEAD PROTECTOR

D202

1A.

D301

1A.

R307

100

SPST GUN SWITCH

D203

1A.

D302

2A.

R308

SPDT INTERLOCK SWITCH

D204

1A.

D303

3A.

R309

SPDT DIRECTION SWITCH

D205

1A.

D304

4A.

R310

R201

40 12W

FOR CONTROL P.C. BOARDS L5767-1 AND HIGHER, USE

DZ301

62V

R311

M16802 SCHEMATIC FOR COMPONENT VALUES AND

R202

100

DZ302

10V

S304

POWER SOURCE

CIRCUIT CONNECTIONS

R203

100K

Q301

2N3393

SELECTOR SWITCH

FOR VARIABLE VOLTAGE P.C. BOARD L5039-1 OR HIGHER,

R204

Q302

2N4125

UJT

USE M16441 SCHEMATIC FOR COMPONENT VALUES AND

R205

4.7K

R206

PT301

1:1:1 PULSE TRANSFORMER

F201

1/2A 125V CR 250V

TP301

TRANSIENT PROTECTION

VARIABLE VOLTAGE CIRCUIT (BOARD #3)

QU301

2W
TRIMMER

CIRCUIT CONNECTIONS
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT
BOARD MAY CHANGE WITHOUT AFFECTING THE INTER-

SLOW BLOW FUSE
SCR201
TP201

4A 400V
TRANSIENT PROTECTION

COMPONENTS NOT ON P.C. BOARD

ELECTRICAL SYMBOLS
PER E1537

LEAD COLOR CODING

CHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM

B - BLACK

R - RED

MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY

U - BLUE

W - WHITE

OF CONTROLS HAVING A COMMON CODE NUMBER.
12-3-92E
M14680

LN-8

Return to Master TOC

ELECTRICAL DIAGRAMS

G-5

CONTROL BOARD (L5767) SCHEMATIC

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-5

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

LN-8

Return to Master TOC

ELECTRICAL DIAGRAMS

G-6

VARIABLE VOLTAGE BOARD (L5039) SCHEMATIC

Return to Master TOC
Return to Master TOC

Return to Master TOC

Return to Section TOC
Return to Section TOC

Return to Section TOC

G-6

12-3-92E

LN-8

L5767-1
CONTROL
LN-8

BAL

CAL

D6
D7

Return to Master TOC
Return to Master TOC

Return to Section TOC

Return to Master TOC

ITEM

Return to Master TOC

Return to Section TOC

CONTROL BOARD (L5767) LAYOUT

12 3 4 5 6 7 8

Return to Section TOC

G-7

ELECTRICAL DIAGRAMS

O
N

Return to Section TOC

G-7

1-24-97B

L5767-1

REQ’D.

PART No.

IDENTIFICATION

S13490-42

1.0/35

S13490-67

2/50

S13490-104

39uF/20V

S13490-25

4.7/35

T11577-26

.1/100

C6,C10,C11,C12,C13

S16668-5

.022/50

C7,C8

S13490-102

.047/100

T11577-52

.0047 or .005/1400

D1,D2,D8,D9,D10,D11,D12,D13,D14

T12199-1

1N4004

D3,D4

T12199-2

1N4007

DZ1

T12702-4

IN4747

DZ2

T12702-29

1N4744A

T12218-2

5.6mH

PT1

T12737-2

1:1:1

Q1,Q3

T12704-69

2N4403

T12704-68

2N4401

QU1

T12707-4

2N6027

S19400-6811

T10812-73

R3,R14,R16,R22

S19400-1002

R5,R6

S19400-4751

S19400-15R0

R8,R9

S19400-3322

R10

S19400-7500

R11

T10812-39

R12

S19400-2672

R13

S19400-3922

R15

S19400-6812

R17

S19400-2212

R18,R25

T14648-11

R19

S19400-5622

R20,R29

S19400-1502

R21

S19400-1501

R23

T14764-2

.25 7W

R24,R26

T10812-68

1K 1/2W

R27

S19400-1500

R28,R31

S19400-5110

R30

S19400-5232

SCR1,SCR2

S15161-6

2N6397

TP1

T13640-11

45J

2K 1/2W

50K 1/2W

4700 5W

CAPACITORS = MFD/VOLTS
RESISTORS = OHMS/ 1/4W UNLESS OTHERWISE SPECIFIED
INDUCTANCE = HENRYS

LN-8

G-8

ELECTRICAL DIAGRAMS

VARIABLE VOLTAGE BOARD (L5039) LAYOUT
REQ’D

PART NO.

IDENTIFICATION

ITEM

L5039-1

Return to Master TOC
Return to Master TOC

LN-8 VARIABLE VOLTAGE

Return to Section TOC
Return to Section TOC

Return to Master TOC

Return to Section TOC

G-8

CAPACITORS = MFD VOLTS

Return to Master TOC

Return to Section TOC

INDUCTANCE = HENRY

8-31-2001E
L5039-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

LN-8

Return to Master TOC

We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.

Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199

Return to Master TOC

Return to Section TOC
Return to Section TOC

SVM ERROR REPORTING FORM

FAX 216-481-2309

SVM Number ___________________________
Page Number if necessary__________________

Return to Section TOC

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Your Company__________________________
Your Name_____________________________

Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

SD287 01/99

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Lincoln Electric Ln 8 Svm132 A Users Manual Svm132a

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