The machine will run a grinder, but No Weld. Here is what you do.

Information you can use today to troubleshoot your SA200 pipeliner, in the field, yourself.

You will need an ohm meter to check the resistance of the shunt coils.

What to check first!

1.  Try switching your remote control "Off" for the machine.

2. If that resolves the issue, your remote is likely the source of the problem.

3. Check your fine current control, then the rheostat next.

   On the right-hand side of the control panel. Sometimes, a wire will break; sometimes, you can feel it with your hand.

4. To check your rheostat, ensure there are no broken wires. The resistance should range from 0 to 64 ohms as the knob is rotated.

1. Five large cables leave the stator and go to the range switch.

2. You will find two smaller wires, one blue and one brown. Locate them and separate them from the other cables.

3. Cut them as shown in image 1

1. Strip them back so that you can measure the total resistance of the coils.

2. Ensure the internal wire is clean. I prefer using alligator clips to ensure a good connection.

3. If you are using a digital meter (as shown in Image 3), please allow it to be hooked up for several minutes. These coils are large inductors, requiring significant power to test. I prefer to test them with a professional analog VOM.

This is not what you want to see. This customer's machine would not weld. I recommended the customer replace his shunts. He took it to a "friend" who checked and said they were fine. This guy only checks for continuity. He did not understand whay it wouldn't weld?

1. In my experience, exciter coils with a resistance of 38 ohms or less require replacement.  The unit may still weld, but it will generally fail you at the worst possible time!

2. This is a significant undertaking, not complicated, just grunge work. You only want to do it or pay for it once.

   
   

The original Lincoln shunt coils in the octagon stator housing were wound on a sheet metal form with paper insulation. Aluminum wire (nothing wrong with aluminum wire if it is adequately designed) painted with a copper coat. If you are in West Texas, New Mexico, Saudi Arabia, or anywhere with low humidity, they have been known to last fifty years; it's infrequent, but I have personally seen it.

1. If you have an SA200, SA-250, Classic 1, Classic 2, Classic 3, or 200 G, most machines with the octagon barrel starting with a code number have aluminum/paper shunt coils.

2. The only thing you need to keep in mind is that the original Lincoln shunt coils, FJW5-XX, are going to fail. They always died at the worst possible time. I have customers tell me they die in the middle of a weld — usually the last bead you need to finish —on Friday so that you can get paid.

Sorry it's Friday afternoon and I am late for my golf match!

Sorry, our only tech is off doing technical training

1. If you haven't learned yet, there is a critical shortage of competent technical people. The machines are mature technology. It seems that no one knows anything about anything. If you run into some "expert" who bloviates about their expertise, ask them, "Why?" They should be able to answer your question quickly, with no hesitation, with quick, precise answers that can be verified.