Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC i SAFETY i LN-15 FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. __________________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ii SAFETY ii LN-15 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and fi...
Page 4 - iii
POWER MIG 255 SAFETY iii iii Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
POWER MIG 255 SAFETY iv iv Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PRÉCAUTIONS DE SÛRETÉ 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 pr...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; RETURN TO MAIN MENU
POWER MIG 255 v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 7 - TABLE OF CONTENTS
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC X Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation ..............................................................................................................Section A Technical ...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG 255
POWER MIG 255 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC A-2 INSTALLATION A-2 75°C Copper Wire 75°C Copper Wire in Conduit in Conduit Input Ampere AWG (IEC) Sizes ...
Page 9 - Before starting the installation, check with the; SAFETY PRECAUTIONS
POWER MIG 255 INSTALLATION A-3 A-3 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT POWER, GROUNDING ANDCONNECTION DIAGRAMS ---------------------------------------...
Page 10 - FIGURE A.1 — DUAL VOLTAGE MACHINE INPUT CONNECTIONS.
POWER MIG 255 INSTALLATION A-4 A-4 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 4. Using the instructions in Figure A.3, have a qual- ified electrician connect the r...
Page 11 - OUTPUT POLARITY CONNECTIONS; FIGURE A.2 — TRIPLE VOLTAGE MACHINE INPUT CONNECTIONS.
POWER MIG 255 INSTALLATION A-5 A-5 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE A.3 — RECEPTACLE DIAGRAM. CONNECT TO A SYSTEMGROUNDING WIRE. SEETHE UNITED STA...
Page 12 - GUN AND CABLE INSTALLATION
POWER MIG 255 INSTALLATION A-6 A-6 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC GUN AND CABLE INSTALLATION The Magnum 250L gun and cable provided with thePOWER MIG 2...
Page 14 - OPERATION
POWER MIG 255 OPERATION B-2 B-2 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Read entire Operation section beforeoperating the POWER MIG 255. ELECTRIC SHOCK can kill...
Page 15 - PRODUCT DESCRIPTION
POWER MIG 255 OPERATION B-3 B-3 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PRODUCT DESCRIPTION The POWER MIG™ 255 is a complete semiautomaticconstant voltage DC ar...
Page 16 - DESCRIPTION OF CONTROLS; — Place the lever in the “ON”; Voltage Control; — This is a continuous control that; Wire Speed Control; — This controls the wire feed; WIRE DRIVE ROLL; Procedure for; WIRE SIZE CONVERSION PARTS; Accessories; FIGURE B.1 — OPERATOR CONTROLS; LINCOLN
POWER MIG 255 OPERATION B-4 B-4 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC DESCRIPTION OF CONTROLS Power ON/OFF Switch — Place the lever in the “ON” position to en...
Page 17 - CAUTION
POWER MIG 255 OPERATION B-5 B-5 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PROCEDURE FOR CHANGINGDRIVE AND IDLE ROLL SETS 1. Turn off the power source. 2. Release ...
Page 18 - TO START THE WELDER; INSTRUCTIONS TO ENTER SLOW RUN-IN
POWER MIG 255 OPERATION B-6 B-6 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TO START THE WELDER Turn the Power Switch switch to ON. This lights the redLED display l...
Page 19 - MAKING A WELD
POWER MIG 255 OPERATION B-7 B-7 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC NOTE: Arc starting characteristics may be effectedwhen using the fast run-in mode since ...
Page 20 - electrodes have proper surface lubrication.; FAN CONTROL; Welding Procedure Information
POWER MIG 255 OPERATION B-8 B-8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 5. Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubri...
Page 22 - ACCESSORIES; DRIVE ROLL KITS; Wire; English Wire
POWER MIG 255 ACCESSORIES C-2 C-2 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable for t...
Page 24 - SPOOL GUN ADAPTER KIT; WFS Setting
POWER MIG 255 ACCESSORIES C-4 C-4 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SPOOL GUN ADAPTER KIT Remove all input power to the POWER MIG 255before proceeding. --...
Page 26 - MAINTENANCE; • Have a qualified electrician do the maintenance; Perform the following daily:
POWER MIG 255 MAINTENANCE D-2 D-2 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY PRECAUTIONS • Have a qualified electrician do the maintenance and troubleshooti...
Page 29 - GUN HANDLE DISASSEMBLY; To open up the handle:
POWER MIG 255 MAINTENANCE D-5 D-5 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC GUN HANDLE DISASSEMBLY The internal parts of the gun handle may be inspectedor service...
Page 30 - METRIC SIZE
POWER MIG 255 MAINTENANCE D-6 D-6 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES ...
Page 31 - FIGURE E.1 – BLOCK LOGIC DIAGRAM
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC POWER MIG 255 Section E-1 Section E-1 Theory of Operation ...............................................................................................Section E Input Line Voltage and Main Transformer.............
Page 32 - THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic; FIGURE E.2 — INPUT LINE VOLTAGE AND MAIN TRANSFORMER.
POWER MIG 255 THEORY OF OPERATION E-2 E-2 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT LINE VOLTAGEAND MAIN TRANSFORMER The desired single phase input power is...
Page 33 - FIGURE E.3 — OUTPUT RECTIFICATION AND FEEDBACK.
POWER MIG 255 THEORY OF OPERATION E-3 E-3 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT RECTIFICATION ANDFEEDBACK CONTROL The AC output from the main transform...
Page 34 - CONSTANT VOLTAGE OUTPUT
POWER MIG 255 THEORY OF OPERATION E-4 E-4 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CONSTANT VOLTAGE OUTPUT The controlled DC output from the SCR rectifierassembl...
Page 35 - FIGURE E.5 — WIRE DRIVE MOTOR AND FEEDBACK.
POWER MIG 255 THEORY OF OPERATION E-5 E-5 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC WIRE DRIVE MOTOR AND FEEDBACK The wire drive motor is controlled by the contro...
Page 36 - OVERCURRENT PROTECTION
POWER MIG 255 THEORY OF OPERATION E-6 E-6 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC THERMAL AND OVERLOADPROTECTION The POWER MIG 255 has built-in protective ther-...
Page 37 - SCR OPERATION; INPUT
POWER MIG 255 THEORY OF OPERATION E-7 E-7 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SCR OPERATION A silicon controlled rectifier (SCR) is a three terminaldevice u...
Page 38 - NOTES
POWER MIG 255 NOTES E-8 E-8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 39 - Test Procedures
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC POWER MIG 255 Section F-1 Section F-1 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section ........................................................................Sectio...
Page 40 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The; Step 3. PERFORM COMPONENT TESTS
HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician and machineoperator and will invalidate your factory warranty. For your safety and to avo...
Page 41 - PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
POWER MIG 255 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-3 F-3 Sometimes machine failures appear to be due to PCboard failures. Thes...
Page 42 - TROUBLESHOOTING GUIDE; Observe Safety Guidelines; OUTPUT PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 POWER MIG 255 CAUTION If for any reason you do not understand the test procedures o...
Page 45 - FUNCTION PROBLEMS
POWER MIG 255 TROUBLESHOOTING & REPAIR F-7 F-7 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CAUTION If for any reason you do not understand the test procedures o...
Page 46 - WIRE FEEDING PROBLEMS
POWER MIG 255 TROUBLESHOOTING & REPAIR F-8 F-8 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CAUTION If for any reason you do not understand the test procedures o...
Page 47 - WELDING PROBLEMS
POWER MIG 255 TROUBLESHOOTING & REPAIR F-9 F-9 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CAUTION If for any reason you do not understand the test procedures o...
Page 49 - MAIN TRANSFORMER TEST; TEST DESCRIPTION; This procedure will determine if the correct voltages are being:; MATERIALS NEEDED
Service and repair should be performed by only Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result in dangerto the technician or machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe...
Page 50 - TEST PROCEDURE; FIGURE F.1 — G3521 CONTROL PC BOARD AND M19248 SNUBBER PC BOARD; PLUG
POWER MIG 255 F-12 F-12 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR 4. Locate plug J5 and plug J6 on the G3521 control PC board, and J9...
Page 52 - TROUBLESHOOTING AND REPAIR
POWER MIG 255 TROUBLESHOOTING AND REPAIR F-14 F-14 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC c. If any of the voltages tested are incorrect, check for loose or br...
Page 53 - RECTIFIER DIODE BRIDGE TEST; This test will determine if the correct voltages are being:; MATERIALS NEEDED
POWER MIG 255 TROUBLESHOOTING & REPAIR F-15 F-15 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC RECTIFIER DIODE BRIDGE TEST Service and repair should only be perfo...
Page 54 - Connect main input power to the; Disconnect the main AC input power to; RECTIFIER DIODE BRIDGE TESTING (continued); LEAD; RECTIFIER
POWER MIG 255 TROUBLESHOOTING & REPAIR F-16 F-16 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Leads #208R, #209R, and #354 areconnected to the rectifier diode br...
Page 57 - STATIC SCR RECTIFIER ASSEMBLY TEST
POWER MIG 255 TROUBLESHOOTING & REPAIR F-19 F-19 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC STATIC SCR RECTIFIER ASSEMBLY TEST Service and repair should only b...
Page 58 - Ve r i f y t h a t t h e c a p a c i t o r s h a v e; Disconnect main AC input power to the; STATIC SCR RECTIFIER ASSEMBLY TEST (continued)
POWER MIG 255 TROUBLESHOOTING & REPAIR F-20 F-20 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 4. Ve r i f y t h a t t h e c a p a c i t o r s h a v e c o m p l e...
Page 59 - FIGURE F.4 — LOCATION OF
POWER MIG 255 TROUBLESHOOTING & REPAIR F-21 F-21 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.5 — SCR 1 TEST POINTS. 9. Test for high or infinite resist...
Page 61 - ACTIVE SCR RECTIFIER ASSEMBLY TEST
POWER MIG 255 TROUBLESHOOTING & REPAIR F-23 F-23 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ACTIVE SCR RECTIFIER ASSEMBLY TEST Service and repair should only b...
Page 62 - ACTIVE SCR RECTIFIER ASSEMBLY TEST (continued)
POWER MIG 255 TROUBLESHOOTING & REPAIR F-24 F-24 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 4. Ve r i f y t h a t t h e c a p a c i t o r s h a v e c o m p l e...
Page 63 - a. Test the voltage level of the battery.; FIGURE F.8 — SCR TESTER CIRCUIT; Separate leads X2 and X3 from the
POWER MIG 255 TROUBLESHOOTING & REPAIR F-25 F-25 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 8. Use a commercial SCR tester or con- struct the tester circuit sh...
Page 65 - WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
POWER MIG 255 TROUBLESHOOTING & REPAIR F-27 F-27 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST Service and repair sh...
Page 66 - Locate the following leads on plug J1:; Disconnect main input power to the; FIGURE F.9 — PLUG J1 LOCATION ON G3521 PC CONTROL BOARD.; WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)
POWER MIG 255 TROUBLESHOOTING & REPAIR F-28 F-28 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 3. Locate plug J1 on the G3521 control PC board. See Figure F.9. 4....
Page 69 - VOLTS; Scope probes connected at; SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
POWER MIG 255 TROUBLESHOOTING & REPAIR F-31 F-31 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 0 VOLTS 20.0 V 2.5 ms This is a typical DC output voltage waveformg...
Page 70 - MACHINE LOADED TO 250 AMPS AT 26 VDC; TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
POWER MIG 255 TROUBLESHOOTING & REPAIR F-32 F-32 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 0 VOLTS 20.0 V 5 ms MACHINE LOADED TO 250 AMPS AT 26 VDC TYPICAL OU...
Page 71 - MACHINE LOADED TO 220 AMPS AT 22 VDC
POWER MIG 255 TROUBLESHOOTING & REPAIR F-33 F-33 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 0 VOLTS 20.0 V 5 ms MACHINE LOADED TO 220 AMPS AT 22 VDC ABNORMAL O...
Page 73 - TYPICAL SCR GATE VOLTAGE WAVEFORM
POWER MIG 255 TROUBLESHOOTING & REPAIR F-35 F-35 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 0 VOLTS 2.00 V 5 ms TYPICAL SCR GATE VOLTAGE WAVEFORM This is a typ...
Page 75 - DESCRIPTION; Static electricity grounding strap
POWER MIG 255 F-37 F-37 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING AND REPAIR Service and repair should be performed by only Lincoln Electric facto...
Page 76 - CONTROL PC BOARD; REMOVAL AND REPLACEMENT PROCEDURE (Continued); Disconnect main input power the; FIGURE F.10 — WIRING HARNESS
POWER MIG 255 F-38 F-38 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING AND REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (Continued) REMOVA...
Page 77 - NOTE: TOP COVER SHOWN
POWER MIG 255 F-39 F-39 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING AND REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (Continued) 7. Whe...
Page 79 - Large slot head screwdriver
POWER MIG 255 TROUBLESHOOTING & REPAIR F-41 F-41 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Service and repair should be performed by only Lincoln Electric fac...
Page 80 - PROCEDURE; WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (continued)
POWER MIG 255 TROUBLESHOOTING & REPAIR F-42 F-42 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 6. Disconnect the wire connectors J13 and J12 to the motor/gearbox ...
Page 84 - FIGURE F.14 — MIDDLE HEAT SINK; Remove the case side panels using a; FIGURE F.13 — LEFT HEAT SINK; SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
POWER MIG 255 TROUBLESHOOTING & REPAIR F-46 F-46 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 3. Disconnect lead #204 and heavy alu- minum choke lead from the mi...
Page 85 - FIGURE F.15 — RIGHT HEAT SINK LEAD DISCONNECTION.
POWER MIG 255 TROUBLESHOOTING & REPAIR F-47 F-47 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 8. Clear the leads and carefully remove the SCR rectifier assembly....
Page 87 - Wiring diagram
POWER MIG 255 TROUBLESHOOTING & REPAIR F-49 F-49 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC The liquid electrolite in the capacitors is toxic. Do not touch the...
Page 88 - CAPACITOR BANK REMOVAL AND REPLACEMENT (continued)
POWER MIG 255 TROUBLESHOOTING & REPAIR F-50 F-50 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC tive capacitor bank buss bar using a 1/2 in. open end wrench. 6. Re...
Page 89 - Wire cutters
POWER MIG 255 TROUBLESHOOTING & REPAIR F-51 F-51 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Service and repair should be performed by only Lincoln Electric fac...
Page 90 - FIGURE F.17 — MAIN TRANSFORMER REMOVAL.; MAIN TRANSFORMER AND OUTPUT CHOKE
POWER MIG 255 TROUBLESHOOTING & REPAIR F-52 F-52 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 6. Remove the two transformer secondary leads X2 and X3 (braided co...
Page 93 - Slot head screwdriver
POWER MIG 255 TROUBLESHOOTING & REPAIR F-55 F-55 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Service and repair should be performed by only Lincoln Electric fac...
Page 94 - FIGURE F.18 — FAN MOTOR ASSEMBLY REMOVAL.; FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT (continued)
POWER MIG 255 TROUBLESHOOTING & REPAIR F-56 F-56 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC a. Loosen and remove the two nuts and lock washers from the motormo...
Page 95 - INPUT IDLE AMPS AND WATTS; RETEST AFTER REPAIR; Maximum Idle Watts
POWER MIG 255 TROUBLESHOOTING AND REPAIR F-57 F-57 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT IDLE AMPS AND WATTS WIRE SPEED RANGE OPEN CIRCUIT VOLTAGE RETES...
Page 98 - ELECTRICAL DIAGRAMS
G-2 ELECTRICAL DIAGRAMS POWER MIG 255 WIRING DIAGRAM - ENTIRE MACHINE - CODE 10563 - (L10979) 392 325 515B 209S ** 204S 209R 209 209S W 254 256 551 254A 552 COLOR CODE: ELECTRICAL SYMBOLS PER E1537 GENERAL INFORMATION POWER MIG 255 (208/230V) 206B G2 45 J7 45 6 2 78 J11 GUN TRIGGER 2 325 4 3 4 J12 3...
Page 106 - SNUBBER BOARD
G-10 ELECTRICAL DIAGRAMS POWER MIG 255 SNUBBER PC BOARD SCHEMATIC - (S24374) 204S J1 1 J1 8 5W 10 R1 J1 6 J1 2 J1 3 J1 4 400V .68 C2 J1 5 J1 7 5W 10 R2 24 37 4 209R SNUBBER BOARD NONE .022/50V MFD UNLESS OTHERWISE SPECIFIED) POWER SUPPLY SOURCE POINT POWERMIG 255 N.A. OF A COMPLETE ( CONTROLS HAVING...
Page 107 - SNUBBER
G-11 ELECTRICAL DIAGRAMS POWER MIG 255 G-11 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SNUBBER PC BOARD ASSEMBLY - (M19248-1) 19 24 8-1 Ch’ge. Sht. No. XB 3-12-99 ...
Page 108 - SVM ERROR REPORTING FORM; Please give detailed description below:
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional 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 col-umn troubleshoo...
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