Lincoln Electric Power MIG 260 Service Manual
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Lincoln Electric Power MIG 260 Service Manual

Lincoln Electric Power MIG 260 Service Manual

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Power MIG ® 260
For use with machines having Code Numbers:
Power MIG ® 260: 12728
SERVICE MANUAL
SVM291
| Issue D ate 18-Oct
© Lincoln Global, Inc. All Rights Reserved.

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  • Page 1 Power MIG ® 260 For use with machines having Code Numbers: Power MIG ® 260: 12728 SERVICE MANUAL SVM291 | Issue D ate 18-Oct © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...

  • Page 3: Section A: Warnings

    W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    LINCOLN ELECTRIC Power MIG® 260 Service Manual Power MIG® 260 Service Manual Last update: 2018/10/01 POWER MIG® 260 ............................1 Service Manual ..............................1 Troubleshooting & Repair ..........................3 HOW TO USE TROUBLESHOOTING GUIDE ..................... 3 PC BOARD TROUBLESHOOTING PROCEDURES ....................4 Troubleshooting guide ............................
  • Page 7 LINCOLN ELECTRIC Power MIG® 260 Service Manual LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE ................. 51 CASE BACK REMOVAL AND REPLACEMENT PROCEDURE ................53 TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE ..............56 DIODE BRIDGE (D2) REMOVAL AND REPLACEMENT PROCEDURE .............. 59 DISPLAY PC BOARD REMOVAL AND REPLACEMENT PROCEDURE ............... 61 CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE ............

  • Page 8: Troubleshooting & Repair

    Troubleshooting & Repair 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 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.

  • Page 9: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment.

  • Page 10: Troubleshooting Guide

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 11 3. Perform the Fan Test not being exceeded. Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 12 6. Perform the Control PC Board Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 13 7. Perform the Freewheeling Diode (D1) Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 14 3. Perform the Control PC Board Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 15 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 16 Board Test Procedure. clogged. Check or replace. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 17: Error Codes

    LINCOLN ELECTRIC Power MIG® 260 Service Manual Error Codes Observe Safety Guidelines ERROR CODES detailed in the beginning of this manual. ERROR CODE POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION THERMAL 1. Welding duty should not 1. Machine is overloaded. exceed machine rating.

  • Page 18: Test Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 19 LINCOLN ELECTRIC Power MIG® 260 Service Manual 5. Using a 5/16” nutdriver, attach the two longer screws to the left side of the hinge securing the left case side to the machine. 6. Carefully attach the door to the hinge and close the door.

  • Page 20: Line Switch Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 21 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.3 – Line switch location Figure F.4 – Input switch terminal and lead locations...

  • Page 22: Transformer Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 23 LINCOLN ELECTRIC Power MIG® 260 Service Manual Table F.2 – Transformer primary and secondary voltage tests APPROXIMATE DESCRIPTION TEST POINT TEST POINT EXPECTED READING PRIMARY VOLTAGE 240 VAC (230 VAC INPUT SUPPLY) PRIMARY VOLTAGE 225 VAC (230 VAC INPUT SUPPLY)
  • Page 24 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.5 – Transformer location Figure F.6 – 115V receptacle location...
  • Page 25 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.7 – Control board plug and lead locations Figure F.8 – SCR location...
  • Page 26 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.9 – Negative terminal location...

  • Page 27: Diode Bridge (D2) Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 28 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.10 – D2 rectifier schematic and lead locations...

  • Page 29: Display Pc Board Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 30 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.11 – Display board location Figure F.12 – Display board mounting screw locations...
  • Page 31 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.13 – Display board plug locations Figure F.14 – Display board lead locations...

  • Page 32: Control Pc Board Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 33 LINCOLN ELECTRIC Power MIG® 260 Service Manual Table F.5 – Control board voltage tests TEST POINT TEST POINT EXPECTED DESCRIPTION CONDITION (POS) (NEG) READING POWER TO DISPLAY PLUG J2 PIN 7 PLUG J2 PIN 8 42 VDC MACHINE ON. BOARD...
  • Page 34 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.15 – Control board location Figure F.16 – Control board plug and LED locations...
  • Page 35 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.17 – Control board lead locations...

  • Page 36: Gas Solenoids Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 37 LINCOLN ELECTRIC Power MIG® 260 Service Manual 14. Connect 390 and 392 to the main gas solenoid and leads 311 and 312 to the spool gas solenoid. See Wiring Diagram. 15. Perform the Case Cover Replacement Procedure. Figure F.18 – Main and spool gas solenoid locations...
  • Page 38 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.20 – Control board plug J8 and J3 lead locations Figure F.21 – Main and spool gas solenoid lead locations...

  • Page 39: Fan Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 40 LINCOLN ELECTRIC Power MIG® 260 Service Manual Table F.6 – Fan voltage tests TEST POINT TEST POINT EXPECTED READING MACHINE CONDITION PLUG P14 PIN 4 PLUG P14 PIN 1 POWER ON. TRIGGER 40 VDC (LEAD 354A) (LEAD 211C) ENGAGED. PLUG P15 PIN 4 PLUG P15 PIN 1 POWER ON.

  • Page 41: Choke Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 42 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.23 – Choke locations...

  • Page 43: Thermostat(S) Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 44 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.24 – Control board location Figure F.25 – Control board plug J5 lead locations...

  • Page 45: Static Scr Rectifier Assembly Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 46 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.26 – SCR rectifier assembly location Figure F.27 – SCR rectifier assembly test point locations...

  • Page 47: Active Scr Rectifier Assembly Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 48 LINCOLN ELECTRIC Power MIG® 260 Service Manual is functioning. b. If the voltage is 3 to 6 volts only when the switch (SW 2) is closed or there is no voltage when the switch is closed, the SCR is defective.
  • Page 49 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.29 – SCR tester circuit and SCR connections...

  • Page 50: Wire Drive Motor And Tachometer Feedback Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 51 If the 15 VDC is not present and the leads are okay, the control board may be faulty. Perform the Control PC Board Test Procedure. Carefully remove input power from the Power MIG 260 machine. Test for feedback voltage to control board: 18.
  • Page 52 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.30 – Wire drive motor location Figure F.31 – Control board plug J1 plug and lead locations...
  • Page 53 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.32 – Control board plug J1 plug and lead locations...

  • Page 54: Freewheeling Diode (D1) Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 55 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.33 – Freewheeling diode (D1) location...

  • Page 56: Removal And Replacement Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 57 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.34 – Line switch mounting screw location Figure F.35 – Line switch terminal locations...

  • Page 58: Case Back Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 59 LINCOLN ELECTRIC Power MIG® 260 Service Manual 3. Using a 5/16” nutdriver, attach the two screws securing the case back to the shelf. 4. Using a 5/16” nutdriver, attach the three screws securing the case back to the divider panel.
  • Page 60 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.37 – Reconnect panel lead and mounting screw locations...

  • Page 61: Transformer Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 62 LINCOLN ELECTRIC Power MIG® 260 Service Manual REPLACEMENT PROCEDURE 1. Carefully route leads H1, H2, H3, H4, H5, H6 and H7 through the shelf. See Wiring Diagram. 2. Carefully position the new transformer into the machine. 3. Using a 1/2” nutdriver with an extension, attach the four screws, lock washers and flat washers securing the transformer to the machine.
  • Page 63 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.39 – Lead X9 and circuit breaker location Figure F.40 – Transformer terminals X1, X2, X3 and X4 locations...

  • Page 64: Diode Bridge (D2) Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 65 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.41 – Diode bridge (D2) lead locations Figure F.42 – Diode bridge (D2) mounting nut location...

  • Page 66: Display Pc Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 67 LINCOLN ELECTRIC Power MIG® 260 Service Manual 3. Connect plugs X1 and X2 to the display board. See Wiring Diagram. 4. Using a 3/8” nutdriver, attach the nut and lock washer securing the ground lead to the machine. 5. Carefully position the new display board into the machine.
  • Page 68 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.44 – Ground lead location Figure F.45 – Display board plug and ground lead locations...

  • Page 69: Control Pc Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 70 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.46 – Control board plug locations Figure F.47 – Control board mounting screw locations...

  • Page 71: Gas Solenoids Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 72 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.48 – Gas solenoid lead locations...

  • Page 73: Fan Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 74 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.49 – Fan cover mounting screw locations Figure F.50 – Fan mounting screw locations...

  • Page 75: Input Choke Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 76 LINCOLN ELECTRIC Power MIG® 260 Service Manual Perform the Case Cover Replacement Procedure. 7. Perform the Retest After Repair Procedure. Figure F.51 – Choke terminal locations...

  • Page 77: Output Choke Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 78 LINCOLN ELECTRIC Power MIG® 260 Service Manual 5. Connect the choke thermostat leads to the quick-connect terminals at leads 326 and 327. See Wiring Diagram. Perform the Case Cover Replacement Procedure. 7. Perform the Retest After Repair Procedure. Figure F.52 – Output choke terminal locations...

  • Page 79: Thermostat Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 80 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.53 – Thermostat lead locations Figure F.54 – Thermostat mounting hardware locations...

  • Page 81: Scr Rectifier Assembly Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 82 LINCOLN ELECTRIC Power MIG® 260 Service Manual 12. Using two 1/2” open-end wrenches, remove the bolt, nut lock washer and two flat washers securing transformer terminals X2 and X3 to leads 211A and X3A. See Figure F.58. See Wiring Diagram.
  • Page 83 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.55 – Diode bridge (D2) lead locations Figure F.56 – Thermostat lead locations...
  • Page 84 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.57 – Choke terminal to SCR rectifier connection locations Figure F.58 – Transformer connection locations...
  • Page 85 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.59 – SCR rectifier assembly and capacitor bank mounting hardware locations...

  • Page 86: Wire Drive Motor Assembly Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 87 LINCOLN ELECTRIC Power MIG® 260 Service Manual 13. Using a 7/16” nutdriver, remove the screw and lock washer securing the plastic cover to gain access to the drive gear. 14. Using a Phillips screwdriver, remove the screw, lock washer and collar from the drive gear shaft and remove the drive gear.
  • Page 88 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.60 – Gearbox mounting panel, heavy lead and hex head screw locations Figure F.61 – Adjustment arm, inner wire guide and outer wire guide locations...
  • Page 89 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.62 – Drive roll shaft assembly location Figure F.63 – Drive roll gear removal...
  • Page 90 LINCOLN ELECTRIC Power MIG® 260 Service Manual Figure F.64 – Motor gearbox removal...

  • Page 91: Freewheeling Diode (D1) Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 92: Retest After Repair

    LINCOLN ELECTRIC Power MIG® 260 Service Manual RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components.

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