Lincoln Electric 200 Welder Service manual

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PIPELINER® 200
SVM193-A
July, 2009
For use with machines having Code Numbers: 11114, 11316, 11471
10929, 10660, 10913, 11136
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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
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
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WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
PIPELINER® 200
Mar ʻ95
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ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a.
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Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding 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 within applicable OSHA PEL and
ACGIH TLV limits 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.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
PIPELINER® 200
Jan ʻ09
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iii
SAFETY
WELDING and CUTTING
SPARKS can cause fire or
explosion.
6.a. Remove fire hazards from the welding area.If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
CYLINDER may explode
if damaged.
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7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
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6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
PIPELINER® 200
Jan ʻ09
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PRÉCAUTIONS DE SÛRETÉ
SAFETY
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:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.
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 nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
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6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PIPELINER® 200
Mar ʻ93
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Installation (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section AA
Installation (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section AAA
Operation (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Operation (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BB
Operation (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BBB
Accessories (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Accessories (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section CC
Accessories (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section CCC
Maintenance (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Maintenance (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DD
Maintenance (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DDD
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-370
Parts Manual (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-448
Parts Manual (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P504
PIPELINER® 200
I
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A-1
TABLE OF CONTENTS - INSTALLATION SECTION
A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
General Description & Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Installation & Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Trailer, Polarity Controls, Oil, Fuel & Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
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Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
PIPELINER® 200D KUBOTA
INSTALLATION
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A-2
A-2
TECHNICAL SPECIFICATIONS - PIPELINER® 200D KUBOTA (K6090-11)
Make/Model
Kubota
V2203M
Description
INPUT - DIESEL ENGINE
4 Cylinder
4 Cycle
Naturally Aspirated
Water-Cooled
Diesel Engine
Cast Iron Cylinder,
Block/Crankcase
Speed (RPM)
High Idle 1600
Low Idle 1400
Full Load 1600
Displacement
134.1 cu. in
(2.2 ltrs)
Bore x Stroke
3.43” x 3.64”
27.8HP @1600 RPM
Starting
System
12VDC battery
(Group 45, 650
cold crank amps)
1.4 KW Starter
40 A. Alternator
w/ built in reg.
RATED OUTPUT @ 104°F(40°C) - WELDER
DESCRIPTION
200 Amp DC Welder
All Copper Windings
Pure DC Power Generator
Capacities
Fuel: 15 gal
57 L
Oil: 8.0 Qts.
7.6 L
9.5 Qts.
9.0 L
RATED DC OUTPUT
VOLTS @ RATED AMPS
Duty
CYCLE
Fine Adjustments in each Range
DC CURRENT RANGE
LINCOLN PLUS RATING 40V @ 200A
NEMA RATING 28V @ 200A
60%
40-300 Amps
RATED OUTPUT @ 104°F(40°C) - GENERATOR
Auxiliary Power (1)
1.75 kW 15 Amps @ 120V DC @ 35% Duty Cycle
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HEIGHT
45.50(2) in.
(1156 mm)
PHYSICAL DIMENSIONS
WIDTH
24.00 in.
(610 mm)
DEPTH
68.00 in.
(1727 mm)
WEIGHT
1302 lbs.
(592 kg)
(1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity.
When welding, available auxiliary power will be reduced.
(2) Height is to the top of exhaust elbow. Case height is 40.9 in.(1039mm).
PIPELINER® 200D KUBOTA
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A-3
GENERAL DESCRIPTION
INSTALLATION
The Pipeliner® 200D is a heavy duty engine driven DC
arc welding power source capable of providing DC
constant current output for stick welding and DC TIG
welding. With the addition of the optional Wire Feed
Module the Pipeliner® 200D will provide constant voltage output for running the LN-25 wire feeder.
ENGINE IDLER
The Pipeliner® 200D KUBOTA is equipped with an
electronic automatic engine idler. It automatically
increases and decreases engine speed when starting
and stopping welding or using auxiliary power. A builtin time delay permits changing electrodes before the
engine slows to its low idle speed. The “Idler” control
switch on the panel locks the idler in the full speed
position when desired.
The Pipeliner® 200D KUBOTA has Diesel Engine
Protection. In the event of sudden low oil pressure or
high coolant temperature, the engine immediately
shuts down.
WELDER ENCLOSURE
The complete welder is rubber mounted on a rugged
steel “C” channel base.
The optional Remote Control Kit provides a remote
control rheostat for remote fine current and open circuit
voltage adjustment.
The Pipeliner® 200D KUBOTA has a current range of
40-300 DC amps with output ratings as follows:
The unit is also capable of providing 1.75 kw of 120V
DC auxiliary power.
This unit uses the Kubota V2203M Industrial water
cooled diesel engine.
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DESIGN FEATURES
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A-3
CONTROL PANEL
Both the engine and the welder controls are located on
one recessed panel at the exciter end of the machine.
The welder controls consist of a five step “Current
Range Selector” switch and a “Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button,”Glow Plug” button, “Ignition” switch,
“Idler” control switch, hour meter, “Engine Protection”
indicator light, “Remote / Local Switch and Receptacle.
The control panel also contains a three prong grounding type receptacle for auxiliary power, an engine temperature gauge, a battery charging ammeter an oil
pressure gauge and a high idle RPM adjustment knob.
WELDING GENERATOR
The Pipeliner® 200D KUBOTA uses the old style,
round, all copper FJW Generator frame which provides
the customer with the original “Classic” pipe welding
arc.
AUXILIARY POWER
1.75 kw of nominal 120V DC. Output voltage is maintained within ± 10% at all loads up to rated capacity.
The output terminals are placed at the side of the
machine so that they are protected by the door. The
output terminals are labeled (+) and (-).
CRANKING SYSTEM
A 12V electric starter is standard.
AIR CLEANER
Heavy duty two-stage dry type
MUFFLER
A muffler and stainless steel exhaust outlet pipe are
standard.
ENGINE HOUR METER
A meter to record the hours of operation.
ENGINE PROTECTION - The system shuts the engine
down in the event of sudden low oil pressure or high
coolant temperature. A warning light on the control
panel will indicate such a fault. To reset the engine for
restarting, turn the ignition switch off then on. Refer to
Troubleshooting section for all warning light fault
codes.
CUSTOM ARC™ HIGH IDLE RPM (OCV)
ADJUSTMENT - A Potentiometer is mounted on the
Control Panel that allows the operator to adjust the
high idle engine speed between 1450 and 1600
RPMʼS. This is to allow further adjustment of the OCV.
Total OCV adjustment range is about 15 volts.
OIL DRAIN VALVE- A ball valve, hose and clamp are
standard.
REMOTE CONTROL- The Remote/Local switch and
Receptacle are standard.
PIPELINER® 200D KUBOTA
INSTALLATION
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A-4
PRE-OPERATION INSTALLATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
-----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operatorʼs manual.
------------------------------------------------------------------------
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EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not
qualify as a spark arrester. When required by local
regulations, a suitable spark arrester must be installed
and properly maintained.
CAUTION
Use of an incorrect arrester may lead to engine damage or performance loss. Contact the engine manufacturer for specific recommendations.
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LOCATION/VENTILATION
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
The welder should be located to provide an unrestricted flow of clean, cool air. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
CAUTION
A-4
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all sides.
------------------------------------------------------------------------
MACHINE GROUNDING
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.
Some state, local, or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol
is
provided on the welding generator frame foot. In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth
ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Code lists a number of alternate means of grounding
electrical equipment.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trailer or gas cylinder.
• Do not lift machine if lift bale is EQUIPMENT can damaged.
• Do not operate machine while suspended
from lift bale.
------------------------------------------------------------------------
PIPELINER® 200D KUBOTA
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A-5
TRAILER
INSTALLATION
(See Accessories Section)
If the user adapts a non-Lincoln trailer, the user must
assume responsibility that the method of attachment
and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be
considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
4. Typical conditions of use, i.e., travel speed, roughness of surface on which the trailer will be operated; environmental conditions, likely maintenance.
5. Conformance with federal, state and local laws. (1)
(1) Consult your federal, state and local laws regarding specific
requirements for use on public highways.
VEHICLE MOUNTING
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for components such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufactureʼs instructions.
------------------------------------------------------------------------
POLARITY CONTROL AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the studs located below the fuel tank mounting rail. (See size recommendations below.) For positive polarity, connect the electrode cable to the terminal marked “+”. For Negative polarity, connect the
electrode cable to the “-” stud. These connections
should be checked periodically and tightened if necessary.
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
RECOMMENDED COPPER CABLE SIZES
Amps
200
Duty Cycle
60%
A-5
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Up to 200ft.(61m)
1
200 to 250ft.
(61 to 76m)
1/0
PRE-OPERATION SERVICE
CAUTION
READ the engine operating and maintenance instructions supplied with this machine.
WARNING
DIESEL FUEL
can
cause fire
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expansion may cause overflow.
------------------------------------------------------------------------
OIL
DIESEL FUEL ONLY
This unit is supplied from the factory with the engine
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturerʼs recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. DO NOT overfill.
FUEL
Fill the fuel tank with the grade of fuel recommended in
the Engine Operatorʼs manual. Make sure the valve on
the water separator is in the open position.
COOLING SYSTEM
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alternate antifreeze recommendations).
PIPELINER® 200D KUBOTA
INSTALLATION
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A-6
Battery Charging
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and
be careful when boosting, charging
or working near battery.
To prevent EXPLOSION when:
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a)
Installing a new battery - disconnect the negative cable from the old battery first and connect the negative cable to the new battery last
b) Connecting a battery charger - remove the battery from the welder by disconnecting the negative cable first, then the positive cable and
battery clamp. When reinstalling, connect the
negative cable last.
c) Using a booster - connect the positive lead to
the battery first, then connect the negative lead
to the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:
a) Installing a new battery.
b) Using a booster.
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Use correct polarity - Negative Ground.
• To prevent BATTERY DISCHARGE, if you have an
ignition switch, turn it off when engine is not running.
• To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
The PIPELINER® 200D KUBOTA is equipped with a
wet charged battery. The charging current is automatically regulated when the battery is low (after starting
the engine) to a trickle current when the battery is fully
charged.
When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.
PIPELINER® 200D KUBOTA
A-6
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B-1
TABLE OF CONTENTS - OPERATION SECTION
B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
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Idler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
PIPELINER® 200D KUBOTA
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B-2
ENGINE OPERATION
WARNING
OPERATION
COLD WEATHER STARTING:
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
---------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operatorʼs manual.
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Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can
cause overheating.
STARTING THE PIPELINER® 200D KUBOTA V2203M
DIESEL ENGINE
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).
4. Press the Glow Plug button and the Start button at the
same time. When the engine starts running, release
both buttons. If the engine fails to start in 20 seconds,
wait 30 seconds and repeat the above procedure.
5. Observe the oil pressure. If no pressure shows within
30 seconds, stop the engine and consult the engine
operating manual. To stop the engine, turn the “IGNITION” switch to “OFF”.
6. If the engine protection warning light comes on during
cranking or after start up, the “IGNITION” switch must
be turned “OFF” to reset the engine protection system.
7. Allow the engine to run at high idle speed for several
minutes to warm the engine. Stop the engine and
recheck the oil level, after allowing sufficient time for
the oil to drain into the pan. If the level is down, fill it to
the full mark again. The engine controls were properly
set at the factory and should require no adjusting when
received.
B-2
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -5°F (-20°C), it maybe desirable to install coldstarting aides.
Note: Extreme cold weather staring may require longer
glow plug operation.
WARNING
Under NO conditions should ether or other starting
fluids be used!
-----------------------------------------------------------------------HIGH ALTITUDE OPERATION:
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder 4% for every
300 meters (984 ft.) above 1500 meters (4920 ft.).
Contact a Kubota Service Representative for any
engine adjustments that may be required.
STOPPING THE ENGINE
1.
Turn the “IGNITION” switch to “OFF”
At the end of each dayʼs welding, check the crankcase
oil level, drain accumulated dirt and water from the
water separator and refill the fuel tank to minimize
moisture condensation in the tank. Also, running out of
fuel tends to draw dirt into the fuel system.
When hauling the welder between job sites, close the
valve on the water separator.
If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel distribution system. If this happens, bleeding of the fuel
system may be necessary. Use qualified personnel to
do this per the instructions in the MAINTENANCE section of this manual.
ENGINE BREAK-IN
Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
PIPELINER® 200D KUBOTA
OPERATION
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B-3
Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load conditions
for extended periods of time are especially susceptible
to the conditions described above. To accomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engineʼs early life. However, if the welder is
subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.
1. Connect the welder output studs to a suitable
resistive load bank. Note that any attempt to short
the output studs by connecting the welding leads
together, direct shorting of the output studs, or
connecting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty.
2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating
or duty cycle for any period of time will result in
catastrophic damage to the generator and voids
the warranty.
3. Periodically shut off the engine and check the
crankcase oil level.
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WELDER OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
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WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
------------------------------------------------------------------------
B-3
DUTY CYCLE
The NEMA output rating of the PIPELINER® 200D
KUBOTA is 200 amperes at 28 arc volts on a 60% duty
cycle (consult Specifications in this manual for alternate
ratings). Duty cycle is based on a ten minute period;
thus, the welder can be loaded at rated output for six
minutes out of every ten minute period.
CONTROL OF WELDING CURRENT
CAUTION
DO NOT TURN THE “CURRENT RANGE SELECTOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
------------------------------------------------------------------------
The “Current Range Selector” provides five overlapping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.
A high open circuit voltage setting provides the soft
“buttering” arc with best resistance to pop-outs preferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that
still provides the current you need and set the “Fine
Current Adjustment” near maximum. For example: to
obtain 175 amps and a soft arc, set the “Current
Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit voltage.
For example: to obtain 175 amps and a forceful arc,
set the “Current Range Selector” to the 240-160 position and the “Fine Current Adjustment” setting to get
175 amps.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc techniques at settings at the lower end of the open circuit
voltage range.
CAUTION
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
------------------------------------------------------------------------
These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
PIPELINER® 200D KUBOTA
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B-4
OPERATION
IDLER OPERATION
Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
minutes to warm the engine. See Specifications for
operating speeds.
The idler is controlled by the “Idler” toggle switch on
the welder control panel. The switch has two positions
as follows:
1. In the “High”
position, the engine control unit
increases the engine to high idle speed.
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2. In the “Auto”
ates as follows:
/
position, the idler oper-
a. When welding or drawing power for lights or tools
(approximately 100 watts minimum) from the receptacles, the engine operates at high idle speed.
b. When welding ceases or the power load is turned
off, a preset time delay of about 15 seconds starts.
This time delay cannot be adjusted.
c. If the welding or power load is not re-started before
the end of the time delay, the engine control unit
reduces the engine to low idle speed.
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AUXILIARY POWER
1.75 kVA of 120 V DC auxiliary power is availiable at
the receptacle located on the control panel.
When the High Speed Adjustment knob is in the MIN
position, the voltage of the DC auxiliary output may be
reduced to below the rating on the nameplate of the
machine. It is recommended that the High Idle Speed
Adjustment knob should be in the MAX position when
using the DC auxiliary output.
Always replace blown fuse with type rated for DC voltage (i.e. Cooper Bussmann Inc. Model LP-CC-15 or
Littlefuse Model CCMR-15.
Low idle (1400 RPM )
No Load
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PIPELINER® 200D WITH KUBOTA V2203M DIESEL ENGINE
TYPICAL FUEL CONSUMPTION DATA
High idle ( 1600 Rpm )
No load
200 Amps @ 28 Volts
Auxiliary Power
1,750 Watts
.32gal/hr (1.21ltrs/hr )
.37gal/hr (1.40ltrs/hr )
.85gal/hr (3.22ltrs/hr )
.50gal/hr (1.89ltrs/hr)
PIPELINER® 200D KUBOTA
B-4
TABLE OF CONTENTS - ACCESSORIES SECTION
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
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C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
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C-1
PIPELINER® 200D KUBOTA
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C-2
OPTIONAL FEATURES
GENERAL OPTIONS
ACCESSORIES
(Field Installed)
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
-----------------------------------------------------------------------Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.
TRAILER (K953-1) - Two-wheeled trailer with optional fender
and light package. For highway use, consult applicable federal, state, and local laws regarding possible additional requirements. There is a choice of 2 hitches, a fender & a light package.
K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack
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K1858-1 AIR CLEANER SERVICE INDICATOR
STICK OPTIONS
K704 ACCESSORY SET - Includes 35 ft.(10 m) of
electrode cable and 30 ft.(9 m) of work cable, headshield, work clamp and electrode holder. Cable is rated
at 500 amps, 60% duty cycle.
Remote Control Kit (K924-5) - Contains remote
control rheostat and 100 ft.(30.5 m) cable for adjusting
the OCV at the welding site. (For Codes 10910 and
above.)
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Remote Control Kit (K2464-1) - Contains a remote
control rheostat (for adjusting the CC “STICK” OCV),
remote control potentiometer (for adjusting the CV
“WIRE” OCV), and 100ft.(30.5m) cable.
WIRE FEED OPTIONS
C-2
Wire Feed Module (K623-1) - Provides constant voltage (CV) output with improved arc stability for
Innershield welding. Excellent for MIG welding.
Recommended wire feeders are the LN-7, LN-23P and
LN-25. (Factory installed on the K1643-6).
LN-15 Wire Feeder (K1870-1,-2)-Portable CC/CV unit
for flux-cored and MIG welding.
LN-23P Wire Feeder (K316L-1)-Portable CV unit for
Innershield pipe welding. Control cable operates contactor inside Wire Feed Module for “cold” electrode.
Requires LN-23P Adapter Kit (K350-1) and Gun and
Cable Assembly.
LN-23P Adapter Kit (K350-1)-Required to adapt LN23P to any Lincoln power source. Makes 14 pin connection at power source.
Magnum® 250 Innershield Gun (for LN-23P) (K355-10)For lighter weight and easier handling. Rated 250
amps, 60% duty cycle. For .068 through 5/64” (1.7
through 2.0 mm) Innershield wire and includes
reduced speed switch. For pipewelding, an M11476
62° gun tube is recommended.
LN-25 Wire Feeder (K449)-Portable CC/CV unit for
flux-cored and MIG welding. Includes Gas Solenoid &
Internal Contactor. Requires Wire Feed Module.
Remote Voltage Control Kit for LN-25 (K444-2)
Provides 25 ft. (7.5m) of remote output voltage control
and output jumper (2 and 4) for machines having 14
pin MS-type connector.
Magnum® 350 Innershield Gun (for LN-25)(K126-2)For self-shielded wire with 15 ft. (4.5m) cable. For
.062-3/32” (1.6-2.8mm) wire.
Magnum® 200 MIG Gun (for LN-25)(K497-3)-With
15 ft. (4.5m) cable. For .025 (0.6m) wire.
Magnum Gun Connector KiT (K466-1) Connects
Magnum 200 MIG gun to LN-25 Wire Feeder.
62° gun tube for Pipe Welding (KP1909-1)Recommended modification for K355-X or K345-X
guns with 90° gun tubes. Compatible with K126-1,-2
K264-8 and K355-10.
PIPELINER® 200D KUBOTA
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D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions, Bearings, Commutator & Brushes, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Idler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
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Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
PIPELINER® 200D KUBOTA
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D-2
SAFETY PRECAUTIONS
WARNING
MAINTENANCE
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. 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.
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
-----------------------------------------------------------------------GENERAL INSTRUCTIONS
1. Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the current control through its entire range frequently. Good
practice is to turn the handle from maximum to minimum setting twice each morning before starting to
weld.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
D-2
4. When necessary, remove the sediment bowl, if so
equipped, from beneath the fuel tank and clean
out any accumulated dirt and water.
5. Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturerʼs manual.
COOLING SYSTEM
The PIPELINER® 200D KUBOTA is equipped with a
pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the cooling system periodically to prevent clogging the passage and
overheating the engine. When antifreeze is needed,
always use the permanent type.
BEARINGS
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one half ounce of grease per year. A pad
of grease one inch wide, one inch long, and one inch
high weighs approximately one half ounce. Overgreasing is far worse than insufficient greasing.
When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use clean
equipment. More bearing failures are caused by dirt
introduced during greasing than from insufficient
grease.
COMMUTATOR AND BRUSHES
WARNING
Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotating armature when stoning the commutator.
-----------------------------------------------------------------------Shifting of the commutator brushes may result in:
- Change in machine output
- Commutator damage
- Excessive brush wear
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
PIPELINER® 200D KUBOTA
MAINTENANCE
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D-3
Replace brushes when they wear within 1/4”(3.5mm)
of the pigtail. A complete set of replacement brushes
should be kept on hand. Lincoln brushes have a
curved face to fit the commutator. Have an experienced maintenance man seat these brushes by lightly
stoning the commutator as the armature rotates at full
speed until contact is made across the full face of the
brushes. After stoning, blow out the dust with low pressure air.
Arcing or excessive exciter brush wear indicates a possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
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IDLER MAINTENANCE
CAUTION
Before doing electrical work, disconnect the battery.
-----------------------------------------------------------------------When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is connected properly. The correct polarity is negative
ground. Damage to the engine alternator and the
Engine Control Unit can result from incorrect connection.
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1. Proper operation of the idler requires good grounding of the Engine Control Unit, current sensing
printed circuit board and battery.
2. If desired, the welder can be used without automatic idling by setting the “Idler” switch to the “High”
position.
NAMEPLATES
Whenever routine maintenance is performed on this
machine - or at least yearly - inspect all nameplates
and labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replacement
item number.
D-3
PURGING AIR FROM FUEL SYSTEM
(KUBOTA V2203M ENGINE)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
-----------------------------------------------------------------------If the engine is running rough and you suspect air has
been trapped in the fuel system, (e.g. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
1. Fully open the air bleeding valve by turning it
counter clockwise, it is located on top of the fuel
injection pump next to the oil filler. (see figure D.1)
Air Bleeding
Valve
FIGURE D.1
2. Turn the engine by pressing the start button until
the engine runs smoothly (this should take approximately 10 seconds).
3. Fully close the air bleeding valve by turning it clockwise.
Contact your Kubota Engine repair facility if problems
persist.
PIPELINER® 200D KUBOTA
MAINTENANCE
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D-4
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE (50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 150 HOURS OR 4 MONTHS
EVERY 30O HOURS OR 9 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 500 HOURS OR 15 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM
I
I
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R
I
R
R
R
R
C
R
I
I
R
C
R
I
I
I
I
I
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I = Inspect
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D-4
Coolant level
Concentration of antifreeze
Coolant (NOTE 3)
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
Drain water separator & fuel strainer
Fuel filter canister
Tension of alternator drive belt
Alternator drive belt wear
Alternator drive belt
Air filter (earlier check may be req'd)
Air filter element
Valve clearances
Electrical systems
All nuts and bolts for tightness
Leaks or engine damage
Battery
C = Clean
TYPE OR QUANTITY
50/ 50 W at er/ Et hy lene Gly c ol
9. 5 qrt s ., 9. 0L
8. 0 qrt s ., 7. 6L (inc luding filt er)
K ubota # 17480-97010
Donalds on # P 821575
Int ak e . 0071"-. 0086", Ex haus t . 0071"-. 0086"
R = Replace
Notes:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
These preventive maintenance periods apply to average conditions of operation.
If necessary use shorter periods.
PIPELINER® 200D KUBOTA
S25833
MAINTENANCE
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D-5
1. Case Front Assembly
2. Engine Assembly
D-5
3. Exciter Frame, Armature Assembly
4. Generator Frame, Armature & Coupling
5. Fuel Tank Assembly
6. Generator & Exciter Brush Holder Assemblies
7. Base & Lift Bale Assembly
8. Radiator Assembly
Figure D.2 - Major Component Location
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9. Roof & Doors
8
9
2
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1
5
4
7
6
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9
3
6
PIPELINER® 200D KUBOTA
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D-6
NOTES
PIPELINER® 200D KUBOTA
D-6
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AA-1
TABLE OF CONTENTS - INSTALLATION SECTION
AA-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-3
Trailers, Polarity Control & Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-4
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Oil, Fuel, Cooling System & Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-5
PIPELINER® 200D PERKINS
INSTALLATION
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AA-2
AA-2
TECHNICAL SPECIFICATIONS - Pipeliner® 200D (K6090-9)
INPUT - DIESEL ENGINE
Make/Model Description Horsepower Operating Displacement cu. in.(ltrs)
SPEED
Perkins
104.22
4 Cylinder
4 Stroke
Naturally
Aspirated
Water
Cooled
Engine
28.2 HP
@ 1600RPM
Full Load
1550RPM
Low Idle
1400RPM
135.6 (2.2)
12VDC Battery
and starter
Push Button
Starter
(650 Cold
crank amps)
RATED OUTPUT @ 104°F(40C°) - WELDER
DESCRIPTION
RATED DC OUTPUT
VOLTS @ RATED AMPS
Lincoln Plus Rating
40V @ 200A
200 Amp DC Welder
All Copper Windings
Pure DC Power
Generator
High
1600RPM
Starting
System
NEMA Rating
28V @ 200A
Capacities
Fuel: 15gal.(57L)
Oil: 8.7 qts.
(8.2L)
Radiator Coolant
9.5 qts.
(9.0L)
DUTY CYCLE*
DC CURRENT RANGE
Fine Adjustment in each Range
60%
40-300 Amps
RATED OUTPUT @ 104°F(40C°) - GENERATOR
Auxiliary Power 1*
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1.80 kW, 15 Amps @ 120V DC @ 35% Duty Cycle
LUBRICATION
Full Pressure with Full Flow Filter
AIR CLEANER
Single Element
FUEL SYSTEM
Indirect Fuel Injector
Electrical Shutoff Solenoid
Mechanical Fuel Pump
MUFFLER
Low noise Muffler:
Made from long life,
aluminized steel.
ENGINE IDLER
Automatic Idler
HEIGHT
40.94** in.
1039.9 mm
WIDTH
PHYSICAL DIMENSIONS
24.00 in.
609.6 mm
**Top of enclosure, add 8.0” (203.2mm) for exhaust
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ENGINE COMPONENTS
DEPTH
66.50in.
1689.1 mm
GOVERNOR
Mechanical Governor
ENGINE PROTECTION
Shutdown on low oil
pressure and engine
temperature.
WEIGHT
1318 lbs. (598 kg.)
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
* Based on a 10 minute period.
PIPELINER® 200D PERKINS
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AA-3
SAFETY PRECAUTIONS
WARNING
INSTALLATION
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
-----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
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EXHAUST SPARK ARRESTER
Some federal, state, or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The standard mufflers included with these welders do not qualify as spark arresters. When required by local regulations, suitable spark arrester must be installed and
properly maintained.
CAUTION
Use of an incorrect arrester may lead to engine damage or performance loss. Contact the engine manufacturer for specific recommendations.
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LOCATION / VENTILATION
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
The welder should be located to provide an unrestricted flow of clean, cool air. Also, locate the welder so that
engine exhaust fumes are properly vented to an outside area.
CAUTION
AA-3
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all side.
------------------------------------------------------------------------
MACHINE GROUNDING
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.
Some state, local, or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol
is provided on the welding generator frame foot. In
general, if the machine is to be grounded it should be
connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trailer or gas cylinder.
FALLING
• Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury.
• Do not operate machine while
suspended from lift bail.
------------------------------------------------------------------------
PIPELINER® 200D PERKINS
INSTALLATION
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AA-4
TRAILERS (See ACCESSORIES SECTION)
If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment
and usage does not result in a safety hazard, nor damage the welding equipment. Some of the factors to be
considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
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2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; likely maintenance.
5. Conformance with federal, state, and local laws.
(1)
(1)
Consult applicable federal, state, and local laws
regarding specific requirements for use on public highways.
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VEHICLE MOUNTING
WARNING
POLARITY CONTROL AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the studs located below the fuel tank mounting rail. (see size recommendations below). For
Positive polarity, connect the electrode cable to the
terminal marked “Positive”. For Negative polarity,
connect the electrode cable to the “Negative” stud.
These connections should be checked periodically and
tightened if necessary.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
RECOMMENDED COPPER CABLE SIZES
Amps
200
Duty Cycle
60%
Cable Sizes for Combined
Length of Electrode Plus
Work Cable
Up to 200 ft
1
PRE-OPERATION SERVICE
200-250 ft
1/0
CAUTION
READ the engine operating and maintenance
instructions supplied with this machine.
------------------------------------------------------------------------
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for components such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufactureʼs instructions.
------------------------------------------------------------------------
AA-4
DIESEL FUEL
can
cause fire
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expansion may cause overflow.
------------------------------------------------------------------------
PIPELINER® 200D PERKINS
DIESEL FUEL ONLY
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AA-5
OIL
INSTALLATION
This unit is supplied from the factory with the engine
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturers recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. Add if required. DO
NOT OVERFILL.
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FUEL
Fill the fuel tank with the grade of fuel recommended in
the Engine Operatorʼs Manual. Make sure fuel valve on
the sediment bowl and water separator are in the open
position.
COOLING SYSTEM
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed.
(See engine manual or antifreeze container for alternate antifreeze recommendations.)
BATTERY CHARGING
AA-5
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and
be careful when boosting, charging
or working near battery.
To prevent EXPLOSION when:
a)
Installing a new battery - disconnect the negative cable from the old battery first and connect the negative cable to the new battery last
b) Connecting a battery charger - remove the battery from the welder by disconnecting the negative cable first, then the positive cable and
battery clamp. When reinstalling, connect the
negative cable last.
c) Using a booster - connect the positive lead to
the battery first, then connect the negative lead
to the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:
a) Installing a new battery.
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Use correct polarity - Negative Ground.
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b) Using a booster.
• To prevent BATTERY DISCHARGE, if you have an
ignition switch, turn it off when engine is not running.
• To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
The Pipeliner® 200D is equipped with a wet charged
battery. The charging current is automatically regulated when the battery is low (after starting the engine) to
a trickle current when the battery is fully charged.
When replacing, jumping, or otherwise connecting the
battery to the battery cables the proper polarity must
be observed. The correct polarity is NEGATIVE
GROUND.
PIPELINER® 200D PERKINS
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AA-6
NOTES
PIPELINER® 200D PERKINS
AA-6
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BB-1
TABLE OF CONTENTS - OPERATION SECTION
BB-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-1
Safety Precautions & Design Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-2
Engine Operation & Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-3
Welder Operation & Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-4
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Idler Operation & Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-5
PIPELINER® 200D PERKINS
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BB-2
SAFETY PRECAUTIONS
WARNING
OPERATION
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
-----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
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See additional warning information at
front of this operatorʼs manual.
-----------------------------------------------------------------------Operate the welder with the doors closed. Leaving
the doors open changes the designed air flow and
can cause overheating.
------------------------------------------------------------------------
GENERAL DESCRIPTION
The Pipeliner® 200D is a heavy duty engine driven DC
arc welding power source capable of providing DC
constant current output for stick welding and DC TIG
welding. With the addition of the optional Wire Feed
Module the Pipeliner® 200D will provide constant voltage output for running the LN-25 wire feeder.
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The optional Remote Control Kit provides a remote
control rheostat for remote fine current and open circuit
voltage adjustment.
The Pipeliner® 200D has Diesel Engine Protection. In
the event of sudden low oil pressure or high coolant
temperature, the engine immediately shuts down.
BB-2
The Pipeliner® 200D has a current range of 40-300 DC
amps with output ratings as follows:
RATED OUTPUT
200A @ 28V
200A @ 40V
DUTY CYCLE
60%
60%
The unit is also capable of providing 1.80 kw of 120V
DC auxiliary power at 35% duty cycle maximum.
This unit uses the PERKINS 104.22 Industrial water
cooled diesel engine.
DESIGN SUMMARY
Control Panel
Both the engine and the welder controls are located on
one recessed panel at the exciter end of the machine.
The welder controls consist of a five step “Current
Range Selector” switch and a “Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button,”Glow Plug” button, “Ignition” switch,
“Idler” control switch, hour meter, “Engine Protection”
indicator light, “Remote / Local Switch and Receptacle
a battery charging ammeter, an oil pressure gauge and
engine coolant temperature gauge.
The control panel also contains a three prong grounding type receptacle for auxiliary power.
Welding Generator
The Pipeliner® 200D uses the old style, round, all copper FJW Generator frame which provides the customer
with the original “Classic” pipe welding arc.
Engine Idler
The Pipeliner® 200D is equipped with an electronic
automatic engine idler. It automatically increases and
decreases engine speed when starting and stopping
welding or using auxiliary power. A built-in time delay
permits changing electrodes before the engine slows
to its low idle speed. The “Idler” control switch on the
panel locks the idler in the full speed position when
desired.
Auxiliary Power
1.80 kw of nominal 120V DC auxiliary power at 35%
duty cycle maximum. Output voltage is maintained
within ± 10% at all loads up to rated capacity.
Welder Enclosure
The complete welder is rubber mounted on a rugged
steel “C” channel base.
The output terminals are placed at the side of the
machine so that they are protected by the door. The
output terminals are labeled (+) and (-).
PIPELINER® 200D PERKINS
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BB-3
Cranking System
A 12V electric starter is standard.
OPERATION
COLD WEATHER STARTING
Air Cleaner
Heavy duty two-stage dry type
Exhaust
A muffler and stainless steel exhaust outlet pipe are
standard.
Engine Hour Meter
A meter to record the hours of operation.
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ENGINE OPERATION
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can
cause overheating.
STARTING THE PIPELINER® 200D PERKINS
104.22 DIESEL ENGINE
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).
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4. Press the Start button. When the engine starts running, release both buttons. If the engine fails to start
in 20 seconds, wait 30 seconds and repeat the
above procedure.
5. Observe the oil pressure. If no pressure shows within 30 seconds, stop the engine and consult the
engine operating manual. To stop the engine, turn
the “IGNITION” switch to “OFF”.
6. If the engine protection warning light comes on during cranking or after start up, the “IGNITION” switch
must be turned “OFF” to reset the engine protection
system.
7. Allow the engine to run at high idle speed for several minutes to warm the engine. Stop the engine and
recheck the oil level after allowing sufficient time for
the oil drain into the pan. If the level is down, fill it to
the full mark again. The engine controls were properly set at the factory and should require no adjusting when received.
BB-3
With a fully charged battery and a proper weight oil, the
engine should start satisfactorily even down to about 15°F -(26°C). If the engine must be frequently started
at or below -15°F -(26°C), it may be desirable to install
cold-starting aides.
Note: Extreme cold weather starting may require
longer glow plug operation
WARNING
Under NO conditions should ether or other starting
fluids be used!
-----------------------------------------------------------------------STOPPING the ENGINE
1. Turn the “IGNITION” switch to “OFF”
At the end of each dayʼs welding, check the crankcase
oil level, drain accumulated dirt and water from the
sediment bowl under the fuel tank and refill the fuel
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.
When hauling the welder between job sites, close the
fuel feed valve beneath the fuel tank.
If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel distribution system. If this happens, bleeding of the fuel
system may be necessary. Use qualified personnel to
do this per the instructions in the MAINTENANCE section of this manual.
PIPELINER® 200D WITH PERKINS 104.22
DIESEL ENGINE
TYPICAL FUEL CONSUMPTION DATA
Low idle (1400 RPM )
No Load
High idle ( 1800 Rpm )
No load
200 Amps @ 28 Volts
200 Amps @ 40 Volts
Auxiliary Power
15 Amps @ 120 Volts
PIPELINER® 200D PERKINS
.33gal/hr (1.25ltrs/hr )
.39gal/hr (1.48ltrs/hr )
.67gal/hr (2.54ltrs/hr )
.75gal/hr (2.84ltrs/hr )
.50gal/hr (1.89ltrs/hr)
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BB-4
ENGINE BREAK-IN
OPERATION
Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load conditions
for extended periods of time are especially susceptible
to the conditions described above. To accomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engineʼs early life. However, if the welder is
subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.
1. Connect the welder output studs to a suitable
resistive load bank. Note that any attempt to short
the output studs by connecting the welding leads
together, direct shorting of the output studs, or
connecting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty.
2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating
or duty cycle for any period of time will result in
catastrophic damage to the generator and voids
the warranty.
3. Periodically shut off the engine and check the
crankcase oil level.
WELDER OPERATION
BB-4
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
DUTY CYCLE
The NEMA output rating of the Pipeliner® 200D is 200
amperes at 28(1) arc volts on a 60% duty cycle. Duty
cycle is based on a ten minute period; thus, the welder
can be loaded at rated output for six minutes out of
every ten minute period.
(1)
The “Lincoln Plus” output rating at 60% duty cycle
is 200 amperes at 40 Volts.
CONTROL OF WELDING CURRENT
CAUTION
DO NOT TURN THE “CURRENT RANGE SELECTOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
----------------------------------------------------------------------The “Current Range Selector” provides five overlapping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.
A high open circuit voltage setting provides the soft
“buttering” arc with the best resistance to pop-outs preferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that
still provides the current you need and set the “Fine
Current Adjustment” near maximum. For example: to
obtain 175 amps and a soft arc, set the “Current Range
Selector” to the 190-120 position and then adjust the
“Fine Current Adjustment” for 175 amps.
PIPELINER® 200D PERKINS
OPERATION
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BB-5
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit voltage.
For example: to obtain 175 amps and a forceful arc, set
the “Current Range Selector” to the 240-160 position
and the “Fine Current Adjustment” setting to get 175
amps.
CAUTION
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
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-----------------------------------------------------------------------These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
IDLER OPERATION
Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
minutes to warm the engine. See Specifications for
operating speeds.
The idler is controlled by the “Idler” toggle switch on the
welder control panel. The switch has two positions as
follows:
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1. In the “High”
position, the idler solenoid activates, and the engine goes to high idle speed. The
speed is controlled by the governor.
2. In the “Auto”
ates as follows:
/
position, the idler oper-
• When welding or drawing power for lights or tools
(approximately 100-150 watts minimum) from the
receptacle, the idler solenoid activates and the engine
operates at high idle speed.
• When welding ceases or the power load is turned off,
a preset time delay of about 15 seconds starts. This
time delay cannot be adjusted.
• If the welding or power load is not re-started before the
end of the time delay, the idler solenoid deactivates
and reduces the engine to low idle speed.
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AUXILIARY POWER
1.80 kW of 120V DC auxiliary power at 35% duty cycle
maximum is available at the receptacle located on the
control panel.
PIPELINER® 200D PERKINS
BB-5
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BB-6
NOTES
PIPELINER® 200D PERKINS
BB-6
TABLE OF CONTENTS - ACCESSORIES SECTION
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CC-2
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CC-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CC-1
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CC-1
PIPELINER® 200D PERKINS
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CC-2
OPTIONAL FEATURES
ACCESSORIES
(Field Installed)
Accessory Set (K704) - Includes electrode and work
cables, headshield, work clamp and electrode holder.
Remote Control Kit (K924-5) - Contains a remote
control rheostat and 100 ft (30.5m) cable for adjusting
the OCV at the welding site.
Remote Control Kit (K2464-1) - Contains a remote
control rheostat (for adjusting CC “STICK” OCV),
remote control potentiometer (for adjusting CV
“STICK” OCV) and 100ft. (30.5m) cable.
(See Wiring/Connection Diagram Section)
CC-2
Wire Feed Module (K623-1) - Provides constant voltage (CV) output with improved arc stability for
Innershield welding. Excellent for MIG welding.
Recommended wire feeders are the LN-7, LN-23P and
LN-25.
Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.
Oil Drain Kit (K1586-1) - Includes ball valve, hose and
clamp.
Trailer (K957-1) - Two-wheeled trailer for in-plant and
yard towing at speeds under 20 mph only.
Trailer (K953-1) - Two-wheeled trailer with optional
fender and light package. For highway use, consult
applicable federal, state, and local laws regarding possible additional requirements. Choice of 2 hitches and
add on fender & light package.
Order: K953-1
Trailer, K958-1 Ball Hitch, K958-2 Lunette Eye
Hitch, K959-1 Fender & Light Kit.
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
PIPELINER® 200D PERKINS
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DD-1
TABLE OF CONTENTS - MAINTENANCE SECTION
DD-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-2
Bearings, Commutator & Brushes, Idler Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-3
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-4
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Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-5
PIPELINER® 200D PERKINS
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DD-2
SAFETY PRECAUTIONS
WARNING
MAINTENANCE
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. 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.
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
4. When necessary, remove the sediment bowl from
beneath the gas tank and clean out any accumulated dirt and water. Replace the fuel filter in the fuel
line as needed.
5. See the engine manufacturers operation manual for
detailed engine maintenance and troubleshooting
instructions.
COOLING SYSTEM
The Pipeliner® 200D is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodically to prevent clogging the passage and overheating the
engine. When antifreeze is needed, always use the
permanent type.
ENGINE MAINTENANCE
Refer to the Engineʼs operation and maintenance manual for additional information on
the engine.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
------------------------------------------------------------------------
GENERAL INSTRUCTIONS
1. Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the current control through its entire range frequently.
Good practice is to turn the handle from maximum
to minimum setting twice each morning before starting to weld.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
DD-2
PIPELINER® 200D PERKINS
MAINTENANCE
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DD-3
BEARINGS
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one-half ounce of grease per year. A pad
of grease one inch wide, one inch long, and one inch
high weighs approximately one-half ounce. Overgreasing is far worse than insufficient greasing.
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When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use clean
equipment. More bearing failures are caused by dirt
introduced during greasing than from insufficient
grease.
COMMUTATOR AND BRUSHES
WARNING
Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotating armature when stoning the commutator.
-----------------------------------------------------------------------The generator brushes are properly adjusted when the
welder is shipped. They require no particular attention.
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting. Shifting of the brushes may result in:
•
•
•
Change in machine output
Commutator damage
Excessive brush wear
Periodically inspect the commutator and brushes by
removing the covers. DO NOT remove or replace
these covers while the machine is running.
Commutators require little attention. However, if they
are black or appear uneven, have them cleaned by an
experienced maintenance man using fine sandpaper
or a commutator stone. Never use emery cloth or
paper for this purpose.
Replace brushes when they wear within 1/4” of the pigtail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face to fit
the commutator. Have an experienced maintenance
man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact
is made across the full face of the brushes. After stoning, blow out the dust with low pressure air.
IDLER MAINTENANCE
DD-3
CAUTION
Before doing electrical work on the idler printed
circuit board, disconnect the battery.
-----------------------------------------------------------------------When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is connected properly. The correct polarity is negative
ground. Damage to the engine alternator and the printed circuit board can result from incorrect connection.
1. The solenoid plunger must work freely and not bind.
Dust the plunger about once a year with graphite
powder.
2. Proper operation of the idler requires good grounding of the printed circuit board, current sensor and
battery.
3. Idler solenoid is activated for high idle.
4. If desired, the welder can be used without automatic idling by setting the “Idler” switch to the “High”
position.
NAMEPLATES
Whenever routine maintenance is performed on this
machine - or at least yearly - inspect all nameplates
and labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replacement
item number.
PURGING AIR from FUEL
(Perkins 104.22 Engine)
SYSTEM
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
-----------------------------------------------------------------------If the engine is running rough and you suspect air has
been trapped in the fuel system, (EG. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
Arcing or excessive exciter brush wear indicates a possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
PIPELINER® 200D PERKINS
MAINTENANCE
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DD-4
1. Loosen by two or three turns, the vent screw
(Figure DD.1) on the fuel inlet connection.
Vent Screw
DD-4
2. Operate the electric fuel pump by turning the
“Ignition” switch “ON” until fuel, free of air, flows
from the vent point. Tighten the vent screw.
3. Contact your Perkins Engine repair facility if problems persist.
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FIGURE DD.1
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE-(20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 200 HOURS OR 6 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
I
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I
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R R
R R
C C
I
R
I
C C
I
I
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I
R
I
I
MAINTENANCE ITEM
Coolant level
Concentration of antifreeze
R Coolant (NOTE 3)
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
Drain water separator & fuel strainer
Fuel filter canister
Tension of alternator drive belt
Alternator drive belt wear
R Alternator drive belt
Air filter (earlier check may be req'd.)
Air filter element
Check and adjust idle speed
I Tighten cylinder head
I Valve clearances
I Electrical systems
I All nuts and bolts for tightness
Injector performance
Leaks or engine damage
Battery
C = Clean
R = Replace
TYPE OR QUANTITY
50/50 Water/Ethylene Glycol
9.5qrts., 9.0L
8.7qrts, 8.2L (including filter)
Perkins #140517000
Perkins #26560017
Perkins #080109080
Donaldson #P181050, Nelson #70206N
Intake .008", exhaust .008"
Contact Perkins
I = Inspect
Notes:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
These preventive maintenance periods apply to average conditions of operation.
S25557
If necessary use shorter periods.
PIPELINER® 200D PERKINS
MAINTENANCE
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DD-5
1. Case Front Assembly
2. Engine Assembly
DD-5
3. Exciter Frame, Armature Assembly
4. Generator Frame, Armature & Coupling
5. Fuel Tank Assembly
6. Generator & Exciter Brush Holder Assemblies
7. Base & Lift Bale Assembly
8. Idler Solenoid Assembly
9. Radiator Assembly
Figure DD.2 - Major Component Location
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10. Roof & Doors
9
10
2
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1
5
4
8
7
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6
3
10
PIPELINER® 200D PERKINS
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DD-6
NOTES
PIPELINER® 200D PERKINS
DD-6
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AAA-1
TABLE OF CONTENTS - INSTALLATION SECTION
AAA-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-3
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-4
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Pre-Operation Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-5
PIPELINER® 200G
INSTALLATION
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AAA-2
TECHNICAL SPECIFICATIONS - Pipeliner® 200G (K6090-7)
Make/Model
GM
3.0 Liter
Pipeliner® 200G
(K6090-7)
Description
4 Cylinder
4 Cycle
46 HP @
1600 RPM
DESCRIPTION
200 Amp DC Welder
INPUT - GASOLINE ENGINE
Speed (RPM)
High Idle 1600
Displacement
cu. in. (Ltrs.)
Full Load 1600
Low Idle 1360
DUTY CYCLE
Lincoln Plus Rating
40V @ 200A
60%
Generator
NEMA Rating
28V @ 200A
60%
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Fuel: 15gal.(57L)
Oil: 4.5Qts.(4.3L)
Coolant: 9.9 Qts.
(9.4L)
DC CURRENT RANGE
Fine Adjustment in each Range
OUTPUT - GENERATOR
1
ENGINE OPERATING LOAD
Low Idle (1360 RPM)-No Load
High Idle (1600 RPM)-No Load
DC Auxiliary-128 Volts-15 Amps-1600 RPM
50 Amps @ 38 Volts @ 60% Duty Cycle
100 Amps @ 34 Volts @ 60 % Duty Cycle
150 Amps @ 29 Volts @ 60% Duty Cycle
200 Amps @ 40 Volts @ 60 % Duty Cycle
40.94** in.
1039.9 mm
Capacities
40-300 Amps
1.75 kW, 15 Amps @ 120V DC
HEIGHT
Delco Voyager
High Energy
RATED OUTPUT - WELDER
RATED DC OUTPUT*
VOLTS @ RATED AMPS
All Copper Windings
Pure DC Power
Ignition
System
Distributor Type
Electronic
183.0(3.0)
Auxiliary Power
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AAA-2
PHYSICAL DIMENSIONS
WIDTH
24.00 in.
609.6 mm
FUEL CONSUMPTION
.7 gal/hr (2.8 ltrs/hr)
.8 gal/hr (3.1 ltrs/hr)
1.1 gal/hr (4.0 ltrs/hr)
1.04 gal/hr (3.94 ltrs/hr)
1.12 gal/hr (4.25 ltrs/hr)
1.15 gal/hr (4.37 ltrs/hr)
1.34 gal/hr (5.07 ltrs/hr)
DEPTH
**Top of enclosure, add 4.6” (116.8mm) for exhaust
68.16in.
1731.0 mm
WEIGHT
1295.0 lbs. (587kg.)
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
PIPELINER® 200G
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AAA-3
SAFETY PRECAUTIONS
INSTALLATION
LOCATION / VENTILATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
-----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
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------------------------------------------------------------------------
PRE-OPERATION INSTALLATION
EXHAUST SPARK ARRESTER
Some federal, state, or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The standard mufflers included with these welders do not qualify as spark arresters. When required by local regulations, suitable spark arrester must be installed and
properly maintained.
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CAUTION
Use of an incorrect arrester may lead to engine damage or performance loss. Contact the engine manufacturer for specific recommendations.
-----------------------------------------------------------------------
AAA-3
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
The welder should be located to provide an unrestricted flow of clean, cool air. Also, locate the welder so that
engine exhaust fumes are properly vented to an outside area.
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all sides.
------------------------------------------------------------------------
MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
• be grounded to the frame of the welder using a
grounded type plug,
or
• be double insulated.
When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is connected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the section entitled “Standby Power Connections” as well as
the article on grounding in the latest U.S. National
Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the
symbol is provided on the
front of the welder.
PIPELINER® 200G
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AAA-4
ANGLE OF OPERATION
To achieve optimum engine performance the
Pipeliner® 200G should be run in a level position. The
maximum angle of operation for the engine is 60
degrees in a direction to cause the air intake manifold
to be angled up, 45 degrees for the air intake manifold
to be angled down; and 50 degrees for the welder control panel to be angled up or down. If the engine is to
be operated at an angle, provisions must be made for
checking and maintaining the oil level at the normal
(FULL) oil capacity in the crankcase. When operating
the welder at an angle, the effective fuel capacity will
be slightly less than the specified 15 gallons.
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LIFT BAIL
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INSTALLATION
A lift bail is provided for lifting with a hoist.
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trailer or gas cylinder.
• Do not lift machine if lift bale
is damaged. Equipment can
be damaged or cause injury.
• Do not operate machine while
suspended from lift bale.
------------------------------------------------------------------------
TRAILERS (See ACCESSORIES SECTION)
If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment
and usage does not result in a safety hazard, nor damage the welding equipment. Some of the factors to be
considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; likely maintenance.
AAA-4
5. Conformance with federal, state, and local laws. (1)
(1) Consult applicable federal, state, and local laws
regarding specific requirements for use on public highways.
VEHICLE MOUNTING
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.
• Distribute, balance and secure loads so vehicle is
stable under conditions of use.
• Do not exceed maximum rated loads for components such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufactureʼs instructions.
------------------------------------------------------------------------
POLARITY CONTROL AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the studs located below the fuel tank mounting rail. (see size recommendations below). For
Positive polarity, connect the electrode cable to the
terminal marked “Positive”. For Negative polarity,
connect the electrode cable to the “Negative” stud.
These connections should be checked periodically and
tightened if necessary.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
RECOMMENDED COPPER CABLE SIZES
Amps
200
PIPELINER® 200G
Duty Cycle
60%
Cable Sizes for Combined
Length of Electrode Plus
Work Cable
Up to 200 ft
(61.0m)
1
200-250 ft
(61.0-72.2m)
1/0
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AAA-5
PRE-OPERATION SERVICE
CAUTION
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
GASOLINE fumes to clear before starting
can cause fire engine.
or explosion. • Do not overfill tank, fuel expansion may cause overflow.
------------------------------------------------------------------------
OIL
GASOLINE FUEL ONLY
This unit is supplied from the factory with the engine
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturers recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. Add if required. DO
NOT OVERFILL.
FUEL
Fill the fuel tank with the grade of fuel recommended in
the Engine Operatorʼs Manual. Make sure fuel valve on
the sediment bowl is in the open position.
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The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed.
(See engine manual or antifreeze container for alternate antifreeze recommendations.)
AAA-5
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
READ the engine operating and maintenance instructions supplied with this machine.
------------------------------------------------------------------------
COOLING SYSTEM
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INSTALLATION
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and be
careful when boosting, charging or working near battery.
To prevent EXPLOSION when:
a)
Installing a new battery - disconnect the
negative cable from the old battery first and
connect the negative cable to the new battery
last.
b) Connecting a battery charger - remove the
battery from the welder by disconnecting the
negative cable first, then the positive cable and
battery clamp. When reinstalling, connect the
negative cable last.
c) Using a booster - connect the positive lead to
the battery first, then connect the negative lead to
the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:
a) Installing a new battery.
b) Using a booster.
Use correct polarity - Negative Ground.
To prevent BATTERY DISCHARGE, turn ignition
switch off when engine is not running.
• To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
BATTERY CHARGING
The Pipeliner® 200G is equipped with a wet charged
battery. The charging current is automatically regulated when the battery is low (after starting the engine) to
a trickle current when the battery is fully charged.
When replacing, jumping, or otherwise connecting the
battery to the battery cables the proper polarity must
be observed. The correct polarity is NEGATIVE
GROUND.
PIPELINER® 200G
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AAA-6
NOTES
PIPELINER® 200G
AAA-6
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BBB-1
TABLE OF CONTENTS - OPERATION SECTION
BBB-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-1
Safety Precautions & Design Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-2
Engine/Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-3
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Control of Welding Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-4
PIPELINER® 200G
OPERATION
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BBB-2
SAFETY PRECAUTIONS
DESIGN SUMMARY
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
-----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
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See additional warning information at
front of this operatorʼs manual.
-----------------------------------------------------------------------Operate the welder with the doors closed. Leaving
the doors open changes the designed air flow and
can cause overheating.
------------------------------------------------------------------------
GENERAL DESCRIPTION
The Pipeliner® 200G is a heavy duty engine driven DC
arc welding power source capable of providing DC
constant current output for stick welding and DC TIG
welding. With the addition of the optional K623-1 Wire
Feed Module the Pipeliner® 200G will provide constant voltage output for running the LN-25 wire feeder.
The Pipeliner® 200G has a current range of 40-300
DC amps with output ratings as follows:
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RATED OUTPUT
200A @ 28V
200A @ 40V
DUTY CYCLE
60%
60%
The units are also capable of providing 1.75 kw of
115V DC auxiliary power.
This unit uses the GM 3.0L industrial water- cooled
gasoline engine.
BBB-2
Control Panel
Both the engine and the welder controls are located on
one recessed panel at the exciter end of the machine.
The welder controls consist of a five step “Current
Range Selector” switch and a “Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button, “Ignition” switch, “Idler” control switch,
hour meter, a battery charging ammeter, an oil pressure gauge and engine coolant temperature gauge.
The control panel also contains a three prong grounding type receptacle for auxiliary power.
Welding Generator
The Pipeliner® 200G uses the old style, round, all copper FJW Generator frame which provides the customer
with the original “Classic” pipe welding arc.
Engine Idler
The Pipeliner® 200G is equipped with an electronic
automatic engine idler. It automatically increases and
decreases engine speed when starting and stopping
welding or using auxiliary power. A built-in time delay
permits changing electrodes before the engine slows
to its low idle speed. The “Idler” control switch on the
panel locks the idler in the full speed position when
desired.
Auxiliary Power
1.75 kw of nominal 120V DC. Output voltage is maintained within ± 10% at all loads up to rated capacity.
(See Optional Features for power plug kits).
Welder Enclosure
The complete welder is rubber mounted on a rugged
steel “C” channel base.
The output terminals are placed at the side of the
machine so that they are protected by the door. The
output terminals are labeled (+) and (-).
Ignition System
A High Energy Distributor Type electronic ignition is
standard.
PIPELINER® 200G
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BBB-3
Cranking System
OPERATION
STOPPING THE ENGINE
A 12V electric starter is standard.
• Turn the Ignition switch to “OFF”.
Air Cleaner
At the end of each dayʼs welding, refill the fuel tank to
minimize moisture condensation in the tank. Also, running out of fuel tends to draw dirt into the fuel system.
Heavy duty two-stage dry type
Exhaust
A muffler and stainless steel exhaust outlet pipe are
standard.
Engine Hour Meter
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A meter to record the hours of operation.
When hauling the welder between job sites, close the
fuel feed valve beneath the fuel tank. Refer to engine
“Operation and Maintenance manual” for additional
information on the engine supplied with this welder.
WELDER OPERATION
WARNING
High Idle RPM (OCV) Adjustment- A potentiometer
is mounted on the output rail that allows the operator to
adjust the high idle engine speed between 1500 and
1600 RPM in 20 RPM increments. This is to allow further adjustment of the OCV. Total OCV adjustment
range is about 10 Volts.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
ENGINE OPERATION
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
• Turn the Idler control switch to “HIGH”. (Optional)
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
• Turn the Ignition switch to “ON”.
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STARTING THE GM 3.0L ENGINE
• Press the “Start” button.
• If the engine fails to start in 20 seconds, wait 30 seconds before repeating the above procedure.
• Allow the engine to run at high idle speed for several minutes to warm up. If idle control switch is left in
“Auto” position , engine will run at 1600 RPM until
engine coolant temperature reaches 130°F.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
DUTY CYCLE
The NEMA output rating of the Pipeliner® 200G is 200
amperes at 28(1) arc volts on a 60% duty cycle. Duty
cycle is based on a ten minute period; thus, the welder
can be loaded at rated output for six minutes out of
every ten minute period.
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BBB-3
The Lincoln “plus output” rating at 60% duty cycle is
200 amperes at 40 Volts.
PIPELINER® 200G
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BBB-4
CONTROL OF WELDING CURRENT
CAUTION
OPERATION
IDLER OPERATION
The operating speeds are as follows:
DO NOT TURN THE “CURRENT RANGE SELECTOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
-----------------------------------------------------------------------The “Current Range Selector” provides five overlapping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.
A high open circuit voltage setting provides the soft
“buttering” arc with the best resistance to pop-outs preferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that
still provides the current you need and set the “Fine
Current Adjustment” near maximum. For example: to obtain
175 amps and a soft arc, set the “Current Range Selector” to
the 190-120 position and then adjust the “Fine Current
Adjustment” for 175 amps.
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit voltage.
For example: to obtain 175 amps and a forceful arc, set
the “Current Range Selector” to the 240-160 position
and the “Fine Current Adjustment” setting to get 175
amps.
CAUTION
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
-----------------------------------------------------------------------These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
TBI DEICING SYSTEM
BBB-4
The welder has been designed to allow continuous
year-round operation. Engine coolant is channeled
through the TBI housing to prevent the build up of ice
on the TBI throat around the throttle plate. the electronic controller is programmed to automatically compensate for the build up of ice on the throttle plate.
There will be no noticeable change in the operation of
the welder should icing develop. On start-up, there is a
possibility for the engine to overspeed (to a maximum
of 2000 RPM) for up to 10 seconds after throttle body
icing conditions have occurred. The electronic governor will correct itself for the new operating conditions
and normal operation will resume.
ORDERING
INFO.
K6090-7
ENGINE
GM 3.0L
FULL
LOAD
HIGH
IDLE
16001500
16001500
LOW
IDLE
1360
The idler is controlled by the “Idler” toggle switch on the
welder control panel. The switch has two positions as
follows:
1. In the “High”
position, the idler is off, and the
engine runs at the high speed controlled by the governor. This speed can be adjusted between 1500
and 1600 RPM using the RPM dial on the output
rail.
2. In the “Automatic”
idler operates as follows:
/
position, the
• When welding or drawing power for lights or tools
(approximately 100-150 watts minimum) from the
receptacle, the engine operates at the speed, set
by the RPM dial.
• When welding ceases or the power load is turned
off, a preset time delay of 10 seconds starts. This
time delay cannot be adjusted.
• If the welding or power load is not re-started
before the end of the time delay, the idler reduces
the engine to low idle speed.
AUXILIARY POWER
1.75 kw of 120V DC auxiliary power is available at the
receptacle located on the control panel.
PIPELINER® 200G
TABLE OF CONTENTS - ACCESSORIES SECTION
Optional Equipment & Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CCC-2
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CCC-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CCC-1
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CCC-1
PIPELINER® 200G
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CCC-2
OPTIONAL EQUIPMENT
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(FIELD INSTALLED)
(K704) Accessory Set
Includes 35 ft (10.7m) electrode and 30 ft (9.1m) work
cables, headshield, work clamp, and electrode holder.
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
(K924-4) REMOTE CONTROL
For machines having Code Number 10660:
For “Stick” operation which contains switch, remote
control rheostat and 100 ft (30.5m) or 25 ft (7.6m)
cable. Easy Installation.
CCC-2
(K953-1) TRAILER - Two-wheeled trailer with
optional fender and light package. For highway use,
consult applicable federal, state, and local laws regarding possible additional requirements. There is a choice
of 2 hitches, a fender & a light package. Order:
K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack
(K623-1) WIRE FEED MODULE -Provides con-
stant voltage (CV) output with improved arc stability for
Innershield welding. Also, excellent for MIG welding.
Easy Installation. Recommended wire feeder is the
LN-25.
(K2261-1) OIL DRAIN KIT-Includes ball valve,
hose and clamp.
(K924-5) REMOTE CONTROL
For machines having Code Number 10913:
For “Stick” operation containing remote control rheostat
and 100 ft (30.5m) cable. Easy Installation.
REMOTE CONTROL
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ACCESSORIES
(K2464-1) - Contains
remote control rheostat (for adjusting the CC “STICK”
OCV), remote control potentiometer (for adjusting the
CV “WIRE” OCV), and 100 ft. (30.5m) cable. Easy
Installation.
PIPELINER® 200G
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DDD-1
TABLE OF CONTENTS - MAINTENANCE SECTION
DDD-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-2
Bearings, Commutator & Brushes, Idler Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-3
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-4
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Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-5
PIPELINER® 200G
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DDD-2
SAFETY PRECAUTIONS
WARNING
MAINTENANCE
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. 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.
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.
----------------------------------------------------------------------ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-----------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
------------------------------------------------------------------------
GENERAL INSTRUCTIONS
1. Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
DDD-2
3. Change the crankcase oil and oil filter after the first
50 hours of operation and thereafter at regular
intervals using the proper grade of oil. See the recommendations in the engine operation manual.
4. Inspect the air filter daily - - more often in dusty conditions when necessary clean or replace. The air filter should never be removed while the engine is
running. The air filter element part number is
Donaldson #181050 or Nelson #70206N.
5. When necessary, remove the sediment bowl from
beneath the gas tank and clean out any accumulated dirt and water. Replace the fuel filter in the fuel
line as needed. In an emergency, the fuel filter can
be back-flushed for continued use until a replacement can be obtained.
6. Fan belts tend to loosen after the first 50 hours of
operation. Check engine operation manual and
tighten if necessary. DO NOT OVERTIGHTEN.
7. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
8. See the engine manufacturers operation manual for
detailed engine maintenance and troubleshooting
instructions.
COOLING SYSTEM
The Pipeliner® 200G is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodically to prevent clogging the passage and overheating the
engine. When antifreeze is needed, always use the
permanent type. Capacity = 9.9 Qty. (9.4 liter) Consult
the engine owners manual for the proper frequency
and procedure.
ENGINE MAINTENANCE
Refer to the Engineʼs operation and maintenance manual for additional information on the engine.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the current control through its entire range frequently.
Good practice is to turn the handle from maximum
to minimum setting twice each morning before starting to weld.
PIPELINER® 200G
MAINTENANCE
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DDD-3
BEARINGS
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one-half ounce of grease per year. A pad
of grease one inch wide, one inch long, and one inch
high weighs approximately one-half ounce. Overgreasing is far worse than insufficient greasing.
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When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use clean
equipment. More bearing failures are caused by dirt
introduced during greasing than from insufficient
grease.
COMMUTATOR AND BRUSHES
WARNING
Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotating armature when stoning the commutator.
-----------------------------------------------------------------------The generator brushes are properly adjusted when the
welder is shipped. They require no particular attention.
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting. Shifting of the brushes may result in:
•
•
•
Change in machine output
Commutator damage
Excessive brush wear
Periodically inspect the commutator and brushes by
removing the covers. DO NOT remove or replace
these covers while the machine is running.
Commutators require little attention. However, if they
are black or appear uneven, have them cleaned by an
experienced maintenance man using fine sandpaper
or a commutator stone. Never use emery cloth or
paper for this purpose.
IDLE CONTROL MAINTENANCE
CAUTION
Before doing electrical work on the idler printed
circuit board, disconnect the battery.
------------------------------------------------------------------------
1. Proper operation of the idler requires good grounding of the battery and TBI controller.
2. If desired, the welder can be used without automatic idling by setting the “Idler” switch to the “High
Idle” position.
3. When installing a new battery or using a jumper
battery to start the engine, be sure the battery
polarity is connected properly. The correct polarity
is negative ground. Damage to the engine alternator and the TBI controller board can result from
incorrect connection.
NAMEPLATES
Whenever routine maintenance is performed on this
machine - - or at least yearly - - inspect all nameplates
and labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replacement
item number.
PURGING AIR FROM FUEL SYSTEM
The fuel system operates as follows: The fuel pump
will operate for a maximum of 3 seconds when the ignition switch is turned “ON”. The pump will restart once
the start button is pushed and continue when the
engine starts. To purge the system of air if fuel lines
have been removed, the ignition switch can be toggled
“ON” and “OFF” (at 3 second intervals) until fuel flows
through the fuel return line in the neck of the fuel line.
Replace brushes when they wear within 1/4” of the pigtail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face to fit
the commutator. Have an experienced maintenance
man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact
is made across the full face of the brushes. After stoning, blow out the dust with low pressure air.
Arcing or excessive exciter brush wear indicates a possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
DDD-3
PIPELINER® 200G
MAINTENANCE
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DDD-4
DDD-4
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE-(50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 200 HOURS OR 6 MONTHS
ENGINE SERVICE (NOTE 2)
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EVERY 600 HOURS OR 12 MONTHS
MAINTENANCE ITEM
I
Coolant level
I
R
I
Coolant (NOTE 3)
9.9qrts, (9.4L)
R
R
Engine oil (NOTE 1 & 3)
4.5qrts, (4.3L) (including filter)
R
R
Engine oil filter
AC PF25
Drain fuel bowl
R
I
PSI #32500292
Fuel filter canister
Tension of alternator / Fan belt
Alternator / fan belt wear
I
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50 / 50 water glycol mixture
Engine oil level (NOTE 1)
C C
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Concentration of antifreeze
Radiator for contamination or blockage
I
4
TYPE OR QUANTITY
R
Alternator belt
R
Fan belt
I
Tighten cylinder head
Good Year 11AV1220
R
Spark Plugs (Gap = 0.040")
I
Electrical systems
I
All nuts and bolts for tightness
R
Air filter element
C C
4 - AC R46TS
Air filter (earlier check may be req'd.)
I
Donaldson #P181050 or Nelson #70206N
Leaks or engine damage
I
I = Inspect
Good Year 11AV0955
Battery
C = Clean
BCI GROUP 45
R = Replace
NOTES:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
(4) Clean the air filter if the engine is operating in very dusty conditions.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
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These preventive maintenance periods apply to average conditions of operation.
If necessary use shorter periods.
PIPELINER® 200G
S20919-3
MAINTENANCE
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DDD-5
1. Case Front Assembly
2. Engine Assembly
DDD-5
3. Exciter Frame, Armature Assembly
4. Generator Frame, Armature & Coupling
5. Fuel Tank Assembly
6. Generator & Exciter Brush Holder Assemblies
7. Base & Lift Bale Assembly
8. Radiator Assembly
Figure DDD.1 - Major Component Location
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9. Roof & Doors
8
9
2
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1
5
4
7
6
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9
3
6
PIPELINER® 200G
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DDD-6
NOTES
PIPELINER® 200G
DDD-6
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E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3/5
Generator & Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
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DC Generator Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
ENGINE
FAILURE
LAMP
ENGINE
PROTECTION
LAMP
ENGINE
FAILURE
LAMP
IDLER
SWITCH
ENGINE
CONTROL
UNIT
(ECU)
RPM
CONTROL
ZENITH
THROTTLE
BODY
CONTROLLER
ENG. IGNITION
TEMP.
SENSOR
SWITCH
OIL
SENSOR
SWITCH
WATER
&
AIR TEMP.
SENSOR
ENGINE
SPEED
ACTUATOR
ENGINE
IGNITION
SWITCH
ENGINE
ALTERNATOR
KUBOTA
DIESEL
ENGINE
MAP
SENSOR
IDLER/ENGINE
PROTECTION
P.C. BOARD
TEMP.
GAUGE
IDLER
SWITCH
90 Min.
FUEL
PUMP
STARTER
MOTOR
NEGATIVE
OUTPUT
TERMINAL
+
POSITIVE
OUTPUT
TERMINAL
FUEL
SOLENOID
STARTER
MOTOR
WATER
GAUGE
OIL
PRESSURE &
WATER TEMP.
SENSOR
OIL
SENSOR
SWITCH
ENGINE
IDLER
SOLENOID
SERIES
COILS
RESIDUAL
MAGNETISM
_
PERKINS DIESEL
ENGINE
MECHANICAL
COUPLING
GENERATOR
ARMATURE
GLOW PLUGS
COUPLED TO
GENERATOR
-
TEMP.
SENSOR
SWITCH
ENGINE
ALTERNATOR
G.M.
GASOLINE
ENGINE
Current
Sensing
P.C. Board
Max
OIL
GAUGE
FUEL
PUMP
ENGINE
IGNITION
SWITCH
STARTER
MOTOR
START
RELAY
OIL
GAUGE
CIRCUITRY
ENGINE
SPEED
SENSOR
TO
ENGINE
CONTROL/PROTECTION
MODULE
TO
BATTERY
FUEL
INJECTORS
THROTTLE
PLATE
MOTOR
OIL
GAUGE
TEMP.
GAUGE
IGNITION
SWITCH
FROM CURRENT
SENSING P.C. BOARD
ENGINE
HOUR
METER
IDLER
SWITCH
RPM
CONTROL
FROM CURRENT
SENSING P.C. BOARD
SELECTOR
SWITCH
FROM CURRENT
SENSING P.C. BOARD
ENGINE
HOUR
METER
ENGINE
HOUR
METER
BRUSHES
&
COMMUTATOR
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FIGURE E.1 — BLOCK LOGIC DIAGRAM
COUPLED TO
GENERATOR
SHUNT
FIELD
+
ARMATURE
SHAFT
DC
EXCITER
ARMATURE
+
SHUNT
FIELD
COILS
ENGINE
ALTERNATOR
SERIES
FIELD
15 AMP
FUSE
INTERPOLE
COILS
GLOW PLUGS
RECEPTACLE
120VDC
12 VOLT
BATTERY
12 VOLT
BATTERY
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GENERATOR
FIELD CONTROL
PIPELINER® 200
THEORY OF OPERATION
ENGINE
FAILURE
LAMP
ENGINE
FAILURE
LAMP
RPM
CONTROL
ZENITH
THROTTLE
BODY
CONTROLLER
OIL
GAUGE
TEMP.
GAUGE
OIL
SENSOR
SWITCH
ENGINE
SPEED
SENSOR
WATER
&
AIR TEMP.
SENSOR
ENGINE
SPEED
ACTUATOR
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ENGINE
ALTERNATOR
KUBOTA
DIESEL
ENGINE
MAP
SENSOR
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90 Min.
FUEL
PUMP
STARTER
MOTOR
WATER
GAUGE
OIL
PRESSURE &
WATER TEMP.
SENSOR
OIL
SENSOR
SWITCH
ENGINE
IDLER
SOLENOID
SERIES
COILS
STARTER
MOTOR
NEGATIVE
OUTPUT
TERMINAL
+
POSITIVE
OUTPUT
TERMINAL
RESIDUAL
MAGNETISM
_
MECHANICAL
COUPLING
GENERATOR
ARMATURE
GLOW PLUGS
COUPLED TO
GENERATOR
-
FUEL
SOLENOID
PERKINS DIESEL
ENGINE
ENGINE
ALTERNATOR
G.M.
GASOLINE
ENGINE
Current
Sensing
P.C. Board
Max
TEMP.
SENSOR
SWITCH
COUPLED TO
GENERATOR
SHUNT
FIELD
+
ARMATURE
SHAFT
DC
EXCITER
ARMATURE
+
SHUNT
FIELD
COILS
ENGINE
ALTERNATOR
SERIES
FIELD
15 AMP
FUSE
INTERPOLE
COILS
GLOW PLUGS
RECEPTACLE
120VDC
12 VOLT
BATTERY
12 VOLT
BATTERY
GENERATOR
FIELD CONTROL
GENERAL DESCRIPTION
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IDLER
SWITCH
OIL
GAUGE
FUEL
PUMP
ENGINE
IGNITION
SWITCH
STARTER
MOTOR
START
RELAY
OIL
GAUGE
CIRCUITRY
IDLER/ENGINE
PROTECTION
P.C. BOARD
TEMP.
GAUGE
FUEL
INJECTORS
THROTTLE
PLATE
MOTOR
ENG. IGNITION
TEMP.
SENSOR
SWITCH
TO
ENGINE
CONTROL/PROTECTION
MODULE
TO
BATTERY
IDLER
SWITCH
ENGINE
CONTROL
UNIT
(ECU)
IGNITION
SWITCH
FROM CURRENT
SENSING P.C. BOARD
ENGINE
HOUR
METER
IDLER
SWITCH
RPM
CONTROL
FROM CURRENT
SENSING P.C. BOARD
SELECTOR
SWITCH
FROM CURRENT
SENSING P.C. BOARD
ENGINE
HOUR
METER
ENGINE
HOUR
METER
BRUSHES
&
COMMUTATOR
ENGINE
PROTECTION
LAMP
ENGINE
IGNITION
SWITCH
E-2
FIGURE E.2 — GENERAL DESCRIPTION
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E-2
The PIPELINER® 200 is a heavy duty, engine driven,
DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding. Also, a total of 1750 watts of auxiliary power is
available at the 120VDC receptacle. The PIPELINER®
200 is manufactured with all copper windings.
PIPELINER® 200
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E-3
THEORY OF OPERATION
FIGURE E.3 — ENGINE CONTROL
ENGINE
PROTECTION
LAMP
E-3
FROM CURRENT
SENSING P.C. BOARD
ENGINE
HOUR
METER
IDLER
SWITCH
ENGINE
CONTROL
UNIT
(ECU)
RPM
CONTROL
OIL
GAUGE
TEMP.
GAUGE
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TEMP.
SENSOR
SWITCH
OIL
SENSOR
SWITCH
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ENGINE
SPEED
ACTUATOR
STARTER
MOTOR
START
RELAY
ENGINE
IGNITION
SWITCH
ENGINE
ALTERNATOR
KUBOTA
DIESEL
ENGINE
COUPLED TO
GENERATOR
GLOW PLUGS
BATTERY, STARTER, ENGINE
ALTERNATOR, OIL, & TEMPERATURE
SWITCH CIRCUITS
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ENGINE
SPEED
SENSOR
The 12VDC battery powers the starter motor and,
through the ignition switch, the engine ignition circuitry
(gas models only), the engine alternator, the engine
control protection modules and associated circuits.
See the appropriate block diagram. These engine control and protection modules monitor engine oil pressure, coolant temperature and engine RPM. The system shuts the engine down in the event of a sudden
low oil pressure or high coolant temperature. A warning light on the control panel provides fault codes, or on
some models the engine fault light will glow.
When the welding or auxiliary load is removed a preset
time delay of about 15 seconds starts. After approximately 15 seconds of “no load” the engine control/protection circuitry returns the engine to low idle
RPM.
The engine idle control (solenoid, throttle plates or
actuator) is mechanically connected to the engine.
When welding current or auxiliary power (120VDC) is
drawn through the current sensing P.C. board a small
voltage signal is sent to the engine control circuitry.
This signals the engine control circuitry to increase the
engine RPM. This is accomplished in a variety of
methods depending upon the engine and control/protection being used.
PIPELINER® 200
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E-4
THEORY OF OPERATION
FIGURE E.4 — ENGINE CONTROL
ENGINE
FAILURE
LAMP
IGNITION
SWITCH
ENGINE
HOUR
METER
IDLER/ENGINE
PROTECTION
P.C. BOARD
E-4
FROM CURRENT
SENSING P.C. BOARD
IDLER
SWITCH
TO
BATTERY
TEMP.
GAUGE
OIL
GAUGE
FUEL
PUMP
TEMP.
SENSOR
SWITCH
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STARTER
MOTOR
OIL
SENSOR
SWITCH
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ENGINE
IDLER
SOLENOID
PERKINS DIESEL
ENGINE
ENGINE
ALTERNATOR
COUPLED TO
GENERATOR
GLOW PLUGS
12 VOLT
BATTERY
BATTERY, STARTER, ENGINE
ALTERNATOR, OIL, & TEMPERATURE
SWITCH CIRCUITS
Return to Section TOC
FUEL
SOLENOID
The 12VDC battery powers the starter motor and,
through the ignition switch, the engine ignition circuitry
(gas models only), the engine alternator, the engine
control protection modules and associated circuits.
See the appropriate block diagram. These engine control and protection modules monitor engine oil pressure, coolant temperature and engine RPM. The system shuts the engine down in the event of a sudden
low oil pressure or high coolant temperature. A warning light on the control panel provides fault codes, or on
some models the engine fault light will glow.
When the welding or auxiliary load is removed a preset
time delay of about 15 seconds starts. After approximately 15 seconds of “no load” the engine control/protection circuitry returns the engine to low idle
RPM.
The engine idle control (solenoid, throttle plates or
actuator) is mechanically connected to the engine.
When welding current or auxiliary power (120VDC) is
drawn through the current sensing P.C. board a small
voltage signal is sent to the engine control circuitry.
This signals the engine control circuitry to increase the
engine RPM. This is accomplished in a variety of
methods depending upon the engine and control/protection being used.
PIPELINER® 200
THEORY OF OPERATION
FIGURE E.5 — ENGINE CONTROL
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E-5
ENGINE
FAILURE
LAMP
ZENITH
THROTTLE
BODY
CONTROLLER
OIL
GAUGE
CIRCUITRY
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WATER
&
AIR TEMP.
SENSOR
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MAP
SENSOR
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FUEL
PUMP
WATER
GAUGE
OIL
PRESSURE &
WATER TEMP.
SENSOR
ENGINE
IGNITION
SWITCH
STARTER
MOTOR
G.M.
GASOLINE
ENGINE
COUPLED TO
GENERATOR
ENGINE
ALTERNATOR
12 VOLT
BATTERY
BATTERY, STARTER, ENGINE
ALTERNATOR, OIL, & TEMPERATURE
SWITCH CIRCUITS
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FUEL
INJECTORS
THROTTLE
PLATE
MOTOR
ENG. IGNITION
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FROM CURRENT
SENSING P.C. BOARD
ENGINE
HOUR
METER
IDLER
SWITCH
RPM
CONTROL
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E-5
The 12VDC battery powers the starter motor and,
through the ignition switch, the engine ignition circuitry
(gas models only), the engine alternator, the engine
control protection modules and associated circuits.
See the appropriate block diagram. These engine control and protection modules monitor engine oil pressure, coolant temperature and engine RPM. The system shuts the engine down in the event of a sudden
low oil pressure or high coolant temperature. A warning light on the control panel provides fault codes, or on
some models the engine fault light will glow.
When the welding or auxiliary load is removed a preset
time delay of about 15 seconds starts. After approximately 15 seconds of “no load” the engine control/protection circuitry returns the engine to low idle
RPM.
The engine idle control (solenoid, throttle plates or
actuator) is mechanically connected to the engine.
When welding current or auxiliary power (120VDC) is
drawn through the current sensing P.C. board a small
voltage signal is sent to the engine control circuitry.
This signals the engine control circuitry to increase the
engine RPM. This is accomplished in a variety of
methods depending upon the engine and control/protection being used.
PIPELINER® 200
THEORY OF OPERATION
TO
ENGINE
CONTROL/PROTECTION
MODULE
SELECTOR
SWITCH
90 Min.
Current
Sensing
P.C. Board
Max
SERIES
COILS
GENERATOR
ARMATURE
BRUSHES
&
COMMUTATOR
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MECHANICAL
COUPLING
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POSITIVE
OUTPUT
TERMINAL
DC
EXCITER
ARMATURE
SERIES
FIELD
15 AMP
FUSE
INTERPOLE
COILS
RECEPTACLE
120VDC
GENERATOR
FIELD CONTROL
EXCITATION (FLASHING)
The main generator armature and the exciter armature
are mechanically coupled to the engine. When the
engine is started and running, the residual magnetism
that is stored in the exciter pole pieces is induced upon
the exciter armature. This causes the exciter to “buildup” and produce a DC output voltage. This DC is
applied, via the field rheostat control, to the main generator shunt field coils. The exciter output is also connected to the 120VDC receptacle.
MAIN SHUNT, INTERPOLE & SERIES COILS
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+
+
ARMATURE
SHAFT
ENGINE, MAIN GENERATOR ARMATURE
& FRAME AND DC EXCITER
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NEGATIVE
OUTPUT
TERMINAL
SHUNT
FIELD
+
SHUNT
FIELD
COILS
-
RESIDUAL
MAGNETISM
_
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E-6
FIGURE E.6 — GENERATOR & EXCITER
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E-6
The generator armature rotates within the magnetic
field created by the shunt field windings. A DC voltage
is induced in the armature and is transferred, through
the armature commutator and brushes, to the series
and interpole coils. The interpole coils, which are connected in series with the positive output terminal, are
located so as to counteract any magnetic influences
that could cause mechanical distortion in the rotating
armature. The series coils are designed to oppose or
“buck” the DC voltage that is generated in the armature.
ENGINE, MAIN GENERATOR ARMATURE, FRAME
& DC EXCITER
CURRENT RANGE SELECTOR
The selector switch acts as a course current adjustment by allowing varying amounts of series windings to
be included in the welding current path. The series
coils and selector switch are connected in series with
the negative output terminal.
FINE CURRENT ADJUSTMENT
The field rheostat control functions as a fine output current adjustment by controlling the current through the
shunt windings, thus controlling the amount of magnetism created in the field windings. Open circuit weld
voltage can also be controlled by the field rheostat control.
PIPELINER® 200
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E-7
THEORY OF OPERATION
FIGURE E.7 — DC GENERATOR THEORY
F
I
E
L
D
C
U
R
R
E
N
T
SHUNT FIELD WINDINGS
DC CURRENT
MAGNETIC FIELD
BRUSH
GENERATOR
MECHANICAL
COUPLING
ARMATURE
SHAFT
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ARMATURE
BRUSH
MAGNETIC FIELD
DC CURRENT
SHUNT FIELD WINDINGS
F
I
E
L
D
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DC GENERATOR MACHINES
The armature winding of a DC generator is located on
the rotating member. Current is conducted from it by
means of carbon brushes. The field winding is located
in the stator, which is stationary and excited by direct
current.
The armature coil sides are placed at opposite points
on the rotating shaft with the conductors parallel to the
shaft. The armature assembly is normally turned at a
constant speed by a source of mechanical power connected to the shaft. When the armature rotates
through the magnetic field produced by the stationary
field winding, it induces a coil voltage in the armature
winding. The voltage induced in an individual armature
coil is an alternating (AC) voltage, which must be rectified. In a conventional DC generator machine, rectification is provided mechanically by means of a commutator. A commutator is a cylinder formed of copper segments insulated from each other and mounted on, but
insulated from, the rotating shaft. Stationary carbon
brushes held against the commutator surface connect
the armature windings to external terminals. The commutator provides full-wave rectification, transforming
the voltage waveform between brushes and making
available a DC voltage to the external circuit.
PIPELINER® 200
C
U
R
R
E
N
T
E-7
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E-8
NOTES
PIPELINER® 200
E-8
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F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
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DC Exciter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Idler Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Main Generator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Flashing The Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23
Engine Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27
Oil Pressure - Temp. Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Current Sensor PCB Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
Engine Throttle Adjustment Test (Perkins Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
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Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41/43
Removal & Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45
DC Armature & Field Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45
Main Generator Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
Main Generator Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-61
Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-63
PIPELINER® 200
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F-2
TROUBLESHOOTING & 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: output 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 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
PIPELINER® 200
F-2
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F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
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.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
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:
PC board can be damaged by static electricity.
- Remove your bodyʼs 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
ATTENTION
Static-Sensitive equipment frame.
Devices
- If you donʼt have a wrist strap,
Handle only at touch an un-painted, grounded,
Static-Safe
part of the equipment frame. Keep
Workstations
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
F-3
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Donʼt set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board canʼt be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
donʼt 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.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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.
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.
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.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
F-4
RECOMMENDED
COURSE OF ACTION
The engine starts and runs at
1. Check for loose or missing
correct speed, but there is no, or
brushes in the DC exciter.
very low, welder output voltage.
2. The exciter may need
There is no DC auxiliary output
“flashing.” See Flashing the
voltage.
Fields in this section.
1. Check for loose or broken
wires between the exciter
brushes and the DC
receptacle and the fine
current control field rheostat.
See the Wiring Diagram.
The engine starts and runs at
1. Check the welding cables for
the correct speed but there is no,
loose or faulty connections.
or very low, welder output. The
2. Check for loose or missing
DC auxiliary output voltage is
brushes in the welding
normal.
generator.
1. Check the fine current control
field rheostat for resistance
and proper operation. Normal
resistance is 64 ohms. Check
associated wires for loose or
faulty connections. See the
Wiring Diagram.
3. Check for open circuit voltage
at weld studs, check heavy
current carrying leads for loose
or corroded connections
2. Perform the DC Exciter Test.
2. Perform the Main Generator
Shunt Field Winding Test.
3. Check the continuity of the
interpole coils. They should
show continuity from the
positive brusholders to the
positive output terminal and
should NOT be grounded to
the generator frame.
4. Check the continuity of the
series coils. They should
show continuity from the
negative brusholders, through
the current selector switch, to
the negative output terminal
and should NOT be grounded
to the generator frame.
5. The main armature may be
faulty. Check for grounds
and/or shorts.
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 1-888-935-3877.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The welding output varies
abnormally. The auxiliary output
remains constant. The engine is
operating correctly.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Check for loose or faulty
welding cables.
2. This may be a normal
condition. The machine will
normally lose some output as
the components are heated.
3. Check for loose, worn, dirty or
poorly seated main DC
generator brushes.
4. The main armature
commutator may need
cleaning.
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F-5
F-5
RECOMMENDED
COURSE OF ACTION
1. Check the fine current control
field rheostat for resistance
and proper operation. Normal
resistance is 64 ohms. Check
associated wires for loose or
faulty connections. See the
Wiring Diagram.
2. Perform the Main Generator
Shunt Field Winding Test.
3. Check the current range
selector switch and contacts
for proper operation.
4. While the machine is loaded,
check the interpole and series
coils for signs of “arcing.”
This condition would indicate
shorted turns in the “arcing”
coil.
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5. The main armature may be
faulty. Check for grounds.
The engine starts and runs at
the correct speed, but there is
no DC auxiliary output voltage
at the 115VDC receptacle. The
welding generator is functioning
correctly.
1. Check the DC receptacle and
plug for loose or faulty
connections.
2. Check the 15 Amp fuse. (Not
on GM 3.0L gas)
CAUTION
1. Check for loose or faulty
connections or wires at the
120 VDC receptacle and
associated circuitry. See the
Wiring Diagram.
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 1-888-935-3877.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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F-6
PROBLEMS
(SYMPTOMS)
The actual welding current is
much less than is indicated on
the dials.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Check the welding cables for
loose or faulty connections.
2. The welding cables may be
excessively long or coiled.
Lincoln Electric Service Dept. 1888-935-3877.
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3. Check the main DC generator
brushes for good commutation
and alignment. Contact the
F-6
RECOMMENDED
COURSE OF ACTION
1. The engine RPM may be low.
If necessary perform the
Engine Throttle Adjustment
Test. (PERKINS code 10929
ONLY)
2. Perform the DC Exciter Test.
3. Check the fine current control
field rheostat for resistance
and proper operation. Normal
resistance is 64 ohms. Check
associated wires for loose or
faulty connections. See the
Wiring Diagram.
4. Check the current range
selector switch and contacts
for proper operation.
5. Perform the Main Generator
Shunt Field Winding Test.
The actual welding current is
much greater than is indicated
on the dials.
1. Check the main DC generator
brushes for good commutation
and alignment. Contact the
Lincoln Electric Service Dept.
1-888-935-3877.
6. The main armature may be
faulty. Check for grounds.
1. The engine operating speed
may be too high. If necessary
perform the Engine Throttle
Adjustment Test. (PERKINS
code 10929 ONLY)
2. While the machine is loaded,
check the series coils for signs
of “arcing.” This condition
could point to shorted turns in
the series coils.
3. Perform the DC Exciter Test.
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 1-888-935-3877.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The engine will not return to low
idle when the welding and
auxiliary loads are removed.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Make sure the idler control
switch is set to the “Auto”
position.
2. Make sure both welding and
auxiliary loads are removed.
3. Check for mechanical
restrictions in the idler and
throttle linkage (PERKINS
code 10929 ONLY) There may
be a problem with the ECU or
Throttle Body Controller or
associated engine control
components on Kubota Diesel
(1114, 11316) and GM
Gas(10660, 10913,
11136)Contact the Lincoln
Electric Service Dept. 1-888935-3877.
CAUTION
F-7
RECOMMENDED
COURSE OF ACTION
1. Check the idler control switch
and associated leads for
loose or faulty connections.
See the Wiring Diagram.
2. Check the CURRENT
SENSING PC BOARD
Perform the Current Sense
Board Test. Replace if
necessary.
3. Perform the Idler Solenoid
Test. (PERKINS 10929
ONLY)
4. Check for loose or faulty
connections at the idler PC
board (PERKINS) ECU in
Kubota and Throttle Body
Controller GM 3.0 liter.
5. The idler PC board
(PERKINS) ECU in Kubota or
Throttle Body Controller -GM
3.0 liter may be faulty.
Contact the Lincoln Electric
Service Dept. 1-888-9353877.
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 1-888-935-3877.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The engine will NOT go to high
speed when a load is applied to
the welding output terminals.
The engine does go to high
speed when a load is applied to
the DC auxiliary power
receptacle. When the engine is
operating in the high RPM
condition, both welding output
and DC auxiliary are normal.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
F-8
RECOMMENDED
COURSE OF ACTION
1. Check welding cables for loose 1. Check the idler control switch
and associated leads for
or faulty connections.
loose or faulty connections.
See the Wiring Diagram.
2. Check the CURRENT
SENSING PC BOARD.
Perform the Current Sense
Board Test. Replace if
necessary.
3. Perform the Idler Solenoid
Test. (PERKINS 10929
ONLY)
4. Check for loose or faulty
connections at the idler PC
board (PERKINS) ECU in
Kubota and Throttle Body
Controller GM 3.0 liter.
5. The idler PC board
(PERKINS) ECU in Kubota or
Throttle Body Controller -GM
3.0 liter may be faulty.
Contact the Lincoln Electric
Service Dept. 1-888-9353877.
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 1-888-935-3877.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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Observe Safety Guidelines detailed in the beginning of this manual.
F-9
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The engine will NOT go to high
speed when a load is applied to
the DC auxiliary receptacle. The
engine does go to high speed
when a load is applied to the
welding output terminals. When
the engine is operating in the
high RPM condition, both
welding output and DC auxiliary
are normal.
1. Check the auxiliary power plug
and associated leads for loose
or faulty connections.
1. Check the idler control switch
and associated leads for
loose or faulty connections.
See the Wiring Diagram.
OUTPUT PROBLEMS
2. The load may be too small.
The load must be above 150
watts.
2. Check the CURRENT
SENSING PC BOARD.
Perform the Current Sense
Board Test. Replace if
necessary.
3. Perform the Idler Solenoid
Test. (PERKINS 10929
ONLY)
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F-9
4. Check for loose or faulty
connections at the idler PC
board (PERKINS) ECU in
Kubota and Throttle Body
Controller GM 3.0 liter.
The engine “cranks” but will not
start.
1. Make sure the ignition switch
is in the ON position.
2. Check for adequate fuel
supply.
CAUTION
5. The idler PC board
(PERKINS) ECU in Kubota or
Throttle Body Controller -GM
3.0 liter may be faulty.
Contact the Lincoln Electric
Service Dept. 1-888-9353877.
1. Check the ignition switch for
proper operation. Check the
associated leads for loose or
faulty connections. See the
Wiring Diagram.
2. Check the fuel solenoid. Make
sure it is opening when
+12VDC is applied.(Except
Kubota) See the Wiring
Diagram.
3. The idler PC board may be
faulty (Perkins 10929)
Replace, OR The ECU Kubota
or Throttle Body Controller GM
3.0 Liter may be faulty. Contact
the Lincoln Electric Service
Dept. 1-888-935-3877.
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 1-888-935-3877.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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F-10
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The engine “cranks” AND starts,
but runs only about 30-60
seconds and shuts down.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELDING PROBLEMS
1. Make sure the correct grade
and amount of oil is in the
engine crankcase. See the
Maintenance Section of this
manual.
2. Make sure the engine is not
overheating.
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3. Make sure the engine
alternator is operating properly.
The welding arc is loud and
spatters excessively.
The welding arc frequently
“pops out”.
1. The current setting may be too
high for the electrode and
process.
2. The polarity may be wrong for
the electrode and process.
1. The fine current control field
rheostat may be set too low for
the process and electrode.
2. Check the welding cables for
loose or faulty connections.
CAUTION
F-10
RECOMMENDED
COURSE OF ACTION
1. The oil pressure switch may
be faulty. Perform the Oil
Pressure Switch Test.
2. The Temperature Switch may
be fault. Perform the
Temperature Switch Test.
3. The alternator may be faulty.
Perform the Alternator Test.
4. The Idler/Engine Protection
Board may be faulty
(PERKINS) The ECU
(KUBO11:29 AMA) or Throttle
Body Controller (GM 3.0 Liter)
may be faulty. Contact the
Lincoln Electric Service Dept.
1-888-935-3877.
1. Check the engine speed.
High idle speed should be
1800 RPM. If Necessary,
perform the Engine Throttle
Adjustment Test. (PERKINS
ONLY 10929)
2. Check the main DC generator
brushes for good commutation
and alignment. Contact the
Lincoln Electric Service Dept.
at 1-888-935-3877.
1. Check the engine speed. High
idle speed should be 1800
RPM. If Necessary, perform the
Engine Throttle Adjustment
Test. (PERKINS ONLY 10929)
2. The Current Range Selector
Switch may be faulty. Check
for proper operation and
contact.
3. Check the DC generator
brushes for good commutation
and alignment. Contact the
Lincoln Electric Service Dept.
at 1-888-935-3877.
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 1-888-935-3877.
PIPELINER® 200
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F-11
LIGHT CODE
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Kubota - EUC - Codes
FAILURE DETECTED
LONG 1, SHORT 1
RPM IS OVER 115% OF RATED RPM (2070 RPM)
LONG 1, SHORT 2
LOW OIL PRESSURE DETECTED FOR 1 SECOND
LONG 1, SHORT 3
"L" TERMINAL IS GROUNDED ON ALTERNATOR
FOR 1 SECOND
LONG 1, SHORT 4
HIGH WATER TEMPERATURE DETECTED
FOR 1 SECOND
LONG 1, SHORT 5
NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT 1
LONG 2, SHORT 2
LONG 2, SHORT 4
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F-11
Observe all Safety Guidelines detailed throughout this manual
LONG 2, SHORT 3
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TROUBLESHOOTING & REPAIR
0 RPM IS DETECTED AND 12V IS DETECTED
FROM "L" TERMINAL ON ALTERNATOR
CURRENT TO ACTUATOR IS OUT OF LIMIT
NOT ENABLED FOR LINCOLN PRODUCTS
-50C WATER TEMPERATURE DETECTED
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
LONG 2, SHORT 6
0 VOLTS DETECTED FROM "L" TERMINAL ON
ALTERNATOR FOR 1 SECOND
LONG 2, SHORT 7
OVER 18 VOLTS DETECTED FROM ALTERNATOR
LONG 2, SHORT 8
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
ACTUATOR SENSED BY ECU
POSSIBLE CAUSE - CORRECTIVE MEASURE
ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY
PLUNGER PULLS IN WHEN ENERGIZED
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK"
STUD IS OPEN WHEN ENGINE IS RUNNING
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE
GROUNDED - CHECK
BROKEN OR LOOSE BELT
LEAD TO "L" TERMINAL ON ALTERNATOR MAYBE
SHORTED TO GROUND- CHECK
FAULTY ALTERNATOR - CHECK
AMOUNT OR QUALITY OF COOLANT INCORRECT
- CHECK
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT
"WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE
GROUNDED - CHECK
FAULTY RPM SENSOR-CHECK FOR GOOD CONNECTION
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD
TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL
RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED
- CHECK
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR
PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN
- CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR
PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE
GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN
- CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
FAULTY ALTERNATOR - CHECK
INCORRECT BATTERY - INSPECT
FAULTY ALTERNATOR - CHECK
FAULTY ECU -CHECK FOR 12 VOLTS ON LEADS TO RPM
SENSOR AND ACTUATOR FROM ECU
PIPELINER® 200
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F-12
NOTES
PIPELINER® 200
F-12
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F-13
TROUBLESHOOTING & REPAIR
DC EXCITER TEST
WARNING
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
or 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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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.
TEST DESCRIPTION
This test will help determine whether or not the DC exciter is operating correctly. If operation is not correct , the test will also determine what component(s) may be faulty.
MATERIALS NEEDED
3/8" wrench
Volt/Ohmmeter (Multimeter)
Wiring Diagram
PIPELINER® 200
F-13
TROUBLESHOOTING & REPAIR
DC EXCITER TEST (CONTINUED)
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F-14
F-14
FIGURE F.1 – 120VDC RECEPTACLE
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SERIES COIL CONNECTION
POINT (NEGATIVE)
POSITIVE
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TEST PROCEDURE
1. Turn off the engine and remove all external loads
to the welder terminals and auxiliary receptacle.
WARNING
MOVING PARTS can injure.
• Remove guards only when necessary
to perform service, and replace them
when the service requiring their
removal is complete.
2. Start the engine and put the idler switch in the HIGH
idle position.
3. Using the volt/ohmmeter, carefully check the DC
voltage at the 120V receptacle. (Observe proper
polarity. The large slot of the receptacle is negative.
See Figure F.1.) Normal voltage is 125 - 135VDC,
no load, with the engine at the high idle speed of
1600 RPM. If the voltage is normal, the DC exciter
is functioning correctly. If the voltage is low or not
present, proceed to the next step.
• Keep hands, hair, clothing and tools away from Vbelts, gears, fans, and all other moving parts when
starting, operating, or repairing equipment.
• If fan guards are missing from a machine, obtain
replacements from a Lincoln Distributor. (See Parts
List.) Always use greatest care when working near
moving parts.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
FIGURE F.2 – EXCITER COVER REMOVAL
WARRANTY
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+
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F-15
DC EXCITER TEST (CONTINUED)
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F-15
EXITER
COVER
CHECK VOLTAGE
AT BRUSH
HOLDERS HERE
(RIGHT SIDE IS +)
4. Turn off the engine. Using the 3/8” nut driver,
remove the exciter cover. See Figure F.2.
5. Start the engine. Using the volt/ohmmeter, carefully check the DC voltage at the brush holders. See
Figure F.2. The right side brush holder is positive
polarity. Normal DC voltage is 125 - 135VDC with
the engine at the high idle speed of 1600 RPM.
6. If the DC voltage is normal at the brush holders, the
DC exciter armature and shunt coils are OK.
a. If the voltage is low or not present, proceed with
the shunt coil and series coil resistance tests.
b. If the correct DC voltage is present at the brush
holders but not at the 120VDC receptacle, the
series coil or associated leads may be faulty.
See the Wiring Diagram. Proceed with the
shunt coil and series coil resistance tests.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
F-16
DC EXCITER TEST (continued)
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F-16
FIGURE F.3 – BRUSH HOLDER LEADS
WARRANTY
WHITE
FLEX
LEAD
RED LEAD -
#2
EXCITER
ARMATURE
EXCITER SERIES FIELD
120 VOLTS
DC
+
-
#1
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T12
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T1
T2
T4
T3
T13
T14
EXCITER SHUNT FIELD
SMALL
FLEX
LEAD
SOLID
LEAD
SHUNT COIL AND SERIES COIL
RESISTANCE TESTS
7. Turn the engine OFF.
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T11
8. Using the 3/8" nut driver, disconnect the two leads
from the left side brush holder. See Figure F.3.
Separate the two leads. One will be a larger
"solid" lead (series coil). The other will be a smaller flex lead (shunt coil).
9. Using the 3/8" nut driver, remove the two flex leads
from the right side brush holder.
Note: Two coils make up a set (L8707), and each coil
consists of two coils, wound together. An Exciter
Shunt Field Coil and an Exciter Series Coil.
10. The coil leads should be disconnected from the
positive and negative brush holder and also the
bolted connection within the exciter bracket that
connects T12 to the RED lead.
11. Using the Ohmmeter, measure the Exciter Series
Coils from the T12 and T2 (heavy stiff magnet
wire) and the Exciter Shunt Field Coils from T4 and
T14 (fine stranded wire) to a good frame ground.
The resistance should be very high (500k Ohms or
higher). This indicates that the coils are not
grounded. If the resistance reading is less than
500k Ohms, this indicates a grounded condition
and replacement should be considered.
12. Using the Ohmmeter, measure Exciter Series
Field Coils from connection T12 to connection T2.
The resistance should be .276 to .296 Ohms.
Measure with the Ohmmeter the Exciter Shunt
Field Coils between T4 and T14, The resistance
should be 127.0 to 133.0 Ohms. If resistance is
very low, the coils are shorted. If coils are warmer
or colder than 25 degrees Celsius, the resistance
will be considerably higher or lower. If coil resistances vary significantly, REPLACEMENT MAY
BE NECESSARY.
13. If the shunt and series coils are good, and the
exciter is not operating properly, the exciter armature may be faulty. Replace the exciter armature.
14. After the test and repairs are completed, install the
exciter cover using the 3/8” nut driver.
PIPELINER® 200
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F-17
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST
WARNING
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
or 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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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.
TEST DESCRIPTION
This test will determine whether or not the idler solenoid can function when it is energized
with 12VDC.
MATERIALS NEEDED
External 12VDC supply
Wiring Diagram
Volt/ohmmeter (Multimeter)
PIPELINER® 200
F-17
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F-18
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST (continued)
F-18
FIGURE F.4 – IDLER SOLENOID CONNECTIONS
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QUICK
CONNECT
LEADS
TEST PROCEDURE
1. Turn the engine OFF.
2. Unlatch and secure the right side door.
3. Locate the idler solenoid and the two leads with
quick connects. See Figure F.4.
4. Disconnect the two solenoid leads at the quick connection splices.
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5. Using the external power supply, apply 12VDC to
the idler solenoid leads. The solenoid should activate.
6. The solenoid should deactivate when the 12VDC is
removed.
7. If the solenoid does not operate properly, check for
a mechanical restriction in the linkage or for a missing spring.
8. If the linkage is intact and the solenoid does not
operate correctly when 12VDC is applied, the idler
solenoid may be faulty. Replace the idler solenoid.
NOTE: Normal solenoid coil resistance is approximately 9 ohms.
9. After the test and repairs are completed, close and
latch the right side door.
PIPELINER® 200
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F-19
TROUBLESHOOTING & REPAIR
MAIN GENERATOR SHUNT FIELD WINDING TEST
WARNING
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
or 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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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.
TEST DESCRIPTION
This test will help determine whether or not the main shunt field coils are shorted, open,
or grounded.
MATERIALS NEEDED
Volt/ohmmeter (Multimeter)
Wiring Diagram
PIPELINER® 200
F-19
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F-20
TROUBLESHOOTING & REPAIR
MAIN GENERATOR SHUNT FIELD WINDING TEST (continued)
FIGURE F.5 – PLUG P10 LOCATION
PLUG P10
TEST PROCEDURE
1. Turn the engine OFF.
2. Unlatch, lift and secure the right side door.
3. Locate plug P10. See Figure F.5.
4. Remove plug P10.
PIPELINER® 200
F-20
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F-21
TROUBLESHOOTING & REPAIR
MAIN GENERATOR SHUNT FIELD WINDING TEST (continued)
FIGURE F.6 – PLUG P10 PIN ASSIGNMENTS
PIN 3
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PIN 5
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TAB
5. Locate the blue (U) (pin 3) and the brown (N)
(pin 5) leads in the harness plug. See
Figure F.6.
6. Using the volt/ohmmeter, measure the resistance between the blue and the brown lead.
Normal resistance is approximately 40
ohms.
7. Also measure the resistance from either
lead (blue or brown) to ground. This resistance should be at least 500,000 ohms.
8. If the test does not meet the resistance
specifications, then check the harness plug
for loose connections or shorted leads.
9. If the plug and associated leads are okay,
the shunt field coils may be faulty. Replace
the shunt field coils.
10. If the test does meet the resistance specifications, the main shunt coils are okay.
11. Replace plug P10, making sure the leads
and plug are secure.
12. After the test and repairs are completed,
close and latch the right side door.
PIPELINER® 200
F-21
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F-22
NOTES
PIPELINER® 200
F-22
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F-23
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS
WARNING
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
or 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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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.
TEST DESCRIPTION
This procedure will magnetize the exciter pole pieces. The exciter can then “build-up”
when the engine is started.
MATERIALS NEEDED
12-volt battery
Two jumper wires with alligator clips on each end
Wiring Diagram
3/8” Nutdriver
PIPELINER® 200
F-23
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F-24
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS (continued)
FIGURE F.7 – EXCITER COVER REMOVAL
EXITER
COVER
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PROCEDURE
1. Turn the engine OFF.
2. Using a 3/8” Nutdriver, remove the exciter cover.
See Figure F.7.
PIPELINER® 200
F-24
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F-25
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS (continued)
F-25
FIGURE F.8 - BRUSH HOLDER/BATTERY JUMPER CONNECTIONS
WARRANTY
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+
RAISE
EXCITER
BRUSH OFF
COMMUTATOR
TO NEGATIVE
BATTERY
TERMINAL
TO POSITIVE
BATTERY
TERMINAL
3. Raise one exciter brush off the armature commutator.
4. Using the jumper leads and the 12VDC battery, first
attach the clip of one lead to the POSITIVE terminal
of the battery. Attach the other end of this same
lead to the right side brush holder. See Figure F.8.
5. Carefully attach one clip of the other lead to the
NEGATIVE terminal of the battery. Attach the other
end of the same lead to the left side brush holder for
approximately five seconds. Pull the lead away
quickly to minimize arcing. See Figure F.8.
6. Remove both leads from the brush holders and the
battery.
7. Install the brush removed in step 3.
8. Install the exciter cover using the 3/8” nut
driver.
9. Start the engine. The exciter should produce DC
output voltage.
PIPELINER® 200
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F-26
NOTES
PIPELINER® 200
F-26
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F-27
TROUBLESHOOTING & REPAIR
ENGINE ALTERNATOR TEST
WARNING
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
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the engine alternator is properly charging the battery.
MATERIALS NEEDED
Miscellaneous Hand Tools
Volt/Ohm Meter
Wiring Diagram
PIPELINER® 200
F-27
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F-28
TROUBLESHOOTING & REPAIR
ENGINE ALTERNATOR TEST (CONTINUED)
FIGURE F.9 - ALTERNATOR LEAD LOCATIONS
BACK OF ALTERNATOR
Alternator
Output
Leads
TEST PROCEDURE
1. Turn the engine off.
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2. Open the engine access door and check the
voltage at the battery terminals. It should be
approximately 12 volts DC.
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F-28
3. Attach the meter leads to the battery terminals,
being careful to position them so they stay
clear of moving parts while the engine is running.
4. Place the idle switch in the “HIGH IDLE” position, start the engine, and allow it to run at high
idle speed for about 15 to 30 seconds.
5. The meter should read about 13.7 to 14.2
VDC.
6. If the meter reads correctly the engine alternator is producing adequate power to charge the
battery and this test is complete.
6. If the voltage is significantly higher than the
above values, the alternator is not properly
regulating the battery charging voltage and
should be replaced. If the voltage reads the
same or less than the measurement taken
when the engine was not running, proceed
with the following tests.
7. Turn off the engine, disconnect the meter from
the battery, and open the engine access door
on the left side of the machine.
8. Make sure the idle switch is still in the “high”
position, start the engine, and allow it to run at
high idle speed for about 15 to 30 seconds.
9. Place the negative meter probe on a good
chassis ground, or the negative battery terminal. Place the positive meter probe on the battery terminal on the back of the alternator.
(Lead #51). See Wiring Diagram.
10. The meter should read about 13.7 to 14.2
VDC.
11. Move the positive probe to the DT terminal on
the back of the alternator. See Wiring
Diagram.
12. The meter should read about 13.7 to 14.2
VDC.
13. If the meter reads correctly, check the connections between the alternator and the battery.
See wiring diagram.
14. If the voltage at both of the above test points
reads the same or less than the battery voltage
measurement taken when the engine was not
running, the alternator is defective. Repair or
replace it.
PIPELINER® 200
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F-29
TROUBLESHOOTING & REPAIR
OIL PRESSURE - TEMPERATURE SWITCH TEST
WARNING
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
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the Oil Pressure and/or Temperature Switch is functioning
properly.
MATERIALS NEEDED
OhmMeter
PIPELINER® 200
F-29
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F-30
TROUBLESHOOTING & REPAIR
OIL PRESSURE - TEMPERATURE SWITCH TEST (CONTINUED)
F-30
FIGURE F.10 - SWITCH
TEMP SW. / SENDER
S25162
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1/4" SPADE TERMINAL
W
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1/2-14 NPT
G
GND
G
OIL SWITCH / SENDER
WK
+ .03
.19 3/16" SPADE TERMINAL
S17026-3
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WK TERMINAL TO GROUND TO CASE AT 6 +/-2 PSI. OTHERWISE TERMINAL TO BE OPEN
Oil Pressure Switch/Sender Resistance Test. S17026-3 (Kubota and Perkins Only)
PROCEDURE
1. With the engine not running locate the Oil
Pressure Switch/Sender.
2. Remove the two leads from the switch.
3. Using the ohmmeter check the resistance from
terminal WK to case ground. This is a normally closed switch and should be at a very low
resistance. (Less than 1 ohm)
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4. Using the ohmmeter check the resistance from
terminal G to case ground. This resistance
should be approximately 10 ohms with zero
PSI oil pressure.
6. With the engine running the resistance from
terminal G to case ground should be as follows.
•
0 PSI equals approximately 10 ohms
•
80 PSI equals approximately 187 ohms
•
40 PSI equals approximately 105 ohms
8. Replace the two leads previously removed.
5. With the engine running and an oil pressure of
6 PSI or greater the resistance from terminal
WK to case ground should be very high.
(open). While the engine is running if the oil
pressure should drop below 6 PSI the switch
would close and shut off the engine.
PIPELINER® 200
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F-31
TROUBLESHOOTING & REPAIR
OIL PRESSURE - TEMPERATURE SWITCH TEST (CONTINUED)
Temperature Switch/Sender Resistance Test. S25162 (Kubota and Perkins Only)
PROCEDURE
1. With the engine not running, and at room
temperature, locate the Temperature
Switch/Sender.
2. Remove the two leads from the switch.
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3. Using the ohmmeter check the resistance from
terminal WK to case ground. This is a normally open switch and should read a very high
resistance.
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F-31
4. This switch should close at approximately
230F. This over temperature condition would
shut off the engine.
6. With engine running the resistance from terminal G to case ground should be as follows.
•
140F equals approximately 134 ohms
•
212F equals approximately 39 ohms
•
194F equals approximately 51 ohms
7. Replace the two leads previously removed.
5. Using the ohmmeter check the resistance from
terminal G to case ground. At room temperature this resistance should be approximately
520 ohms.
PIPELINER® 200
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F-32
NOTES
PIPELINER® 200
F-32
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F-33
TROUBLESHOOTING & REPAIR
CURRENT SENSOR PCB TEST
WARNING
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
or 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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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
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test is used to quickly determine if the current sensor PCB is defective.
MATERIALS NEEDED
Volt/Ohm Meter
Wiring Diagram (See Electrical Diagrams section of this manual)
PIPELINER® 200
F-33
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F-34
TROUBLESHOOTING & REPAIR
CURRENT SENSOR PCB TEST (CONTINUED)
F-34
FIGURE F.11 - CASE COVERS
BOLT / NUT (4)
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“L” DOOR
HOOKS (4)
PROCEDURE
1. Turn the engine off.
2. Remove the four nuts and bolts holding the
case top and doors assembly to the welder
frame. See Figure F.11.
3. Remove the rubber gasket from the top.
Carefully lift up and remove the “L” shaped door
hooks. Locate the Current Sensing P.C. Board
on the inside of the front panel. See Figure
F.12.
4. Turn the engine on and record the voltage
between pins 1 and 2 of J1. See Wiring
Diagram. This voltage should be approximately 12 VDC (battery voltage).
6. Turn the engine on and record the voltage
between pins 4 and 2 on J1. The Idler Switch
must be in the “Auto” position. This voltage
should be approximately 12 VDC (battery voltage). With the engine running load the 115
VDC auxiliary receptacle or strike an arc using
either a load bank or the welding leads.
Observe the Volt/Ohm Meter; the 12 VDC
should drop to zero. If the 12 VDC drops to
zero the current sensor PCB is operating correctly. If the voltage does not drop to zero
replace the current sensor PCB.
5. Turn the engine back OFF and locate pins 4
and 2 on J1 of the Current Sensor PCB and
place the Volt/Ohm Meter leads into the back of
the molex plug.
PIPELINER® 200
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F-35
CURRENT SENSOR PCB TEST (CONTINUED)
TROUBLESHOOTING & REPAIR
FIGURE F.12 - CURRENT SENSING PCB
PIPELINER® 200
F-35
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F-36
NOTES
PIPELINER® 200
F-36
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F-37
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
(PERKINS ONLY)
WARNING
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
or 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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Return to Master TOC
Return to Section TOC
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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.
TEST DESCRIPTION
If the machine output is low, or high, this test will determine whether the engine is operating at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for
adjusting the throttle to the correct RPM are given.
MATERIALS NEEDED
Miscellaneous Hand Tools
Strobe-tach, frequency counter, oscilloscope, white or red marking pencil
PIPELINER® 200
F-37
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F-38
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)
(PERKINS ONLY)
FIGURE F.13 - BLOWER PADDLE MARK LOCATION
BLOWER
PADDLE
MARK
PROCEDURE
Strobe Tach Method
1. Turn the engine off.
2. Unlatch, lift and secure the right side door.
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Note: Latches are located at both ends of the
door.
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F-38
3. Using a white or red marking pencil, place a
mark on one of the blower paddles or on the
side of the flywheel. See Figure F.13 for location.
4. Connect the strobe-tach according to the
manufacturerʼs instructions.
5. Start the engine and direct the strobe-tach light
on the blower paddle. Synchronize it to the
rotating mark.
With the machine at HIGH IDLE the tach
should read between 1540 and 1650 RPM.
With the machine at LOW IDLE the tach should
read between 1375 and 1425 RPM.
PIPELINER® 200
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F-39
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)
(PERKINS ONLY)
PROCEDURE
6. If either of the readings is incorrect, adjust the throttle as follows:
Adjust HIGH IDLE:
The Engine is Preset at factory. Contact Perkins
@ 1-888-737-5364 or www.perkins.com
Adjust LOW IDLE:
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First make sure there is no load on the machine.
Set the IDLE switch to AUTO and wait for the
engine to change to low idle speed.
Use the 7/16” wrench to loosen the solenoid idle
rod locking nut. See Figures F.13 & F.14 Turn the
rod to change the amount of throw in the lever arm,
until the tach reads between 1375 and 1425 RPM.
Retighten the locking nut. Make sure the lever arm
does not contact low speed adjustment stop. Back
stop out if necessary.
PIPELINER® 200
F-39
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F-40
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)
(PERKINS ONLY)
F-40
FIGURE F.14 – SOLENOID LOCATION
IDLER ADJUSTMENT
LOCK NUT
BALL JOINT
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IDLER ROD
PIPELINER® 200
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F-41
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VDC SUPPLY)
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM
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0 volts
2 ms
50 volts
This is the typical auxiliary output
voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division
represents 2 milliseconds in time.
Note: Scope probes connected at
machine 115VDC receptacle.
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SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PIPELINER® 200
F-41
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F-42
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
SWITCH AT MAXIMUM
0 volts
50 volts
5 ms
This is the typical DC welding output
voltage generated from a properly
operating machine. Note that each
vertical division represents 50 volts
and that each horizontal division
represents 5 milliseconds in time.
Note: Scope probes connected at
machine output terminals.
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SCOPE SETTINGS
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F-42
Volts/Div.....................50V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PIPELINER® 200
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F-43
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD VOLTAGE WAVEFORM
MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM
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0 volts
5 ms
20 volts
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MACHINE LOADED TO 200 AMPS AT 40VDC
This is the typical DC welding output
voltage generated from a properly
operating machine. Note that each
vertical division represents 20 volts
and that each horizontal division
represents 5 milliseconds in time.
The machine was loaded with a
resistance grid bank.
Note: Scope probes connected at
machine output terminals.
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SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
PIPELINER® 200
F-43
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F-44
NOTES
PIPELINER® 200
F-44
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F-45
TROUBLESHOOTING & REPAIR
DC EXCITER ARMATURE & FIELD COILS
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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
or 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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Return to Master TOC
Return to Section TOC
Return to Section TOC
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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.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the exciter
armature and field coils.
MATERIALS NEEDED
3/8” Wrench
1/2” Wrench
1-5/8” Socket wrench
Wiring Diagram
PIPELINER® 200
F-45
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TROUBLESHOOTING & REPAIR
DC EXCITER ARMATURE & FIELD COILS
REMOVAL AND REPLACEMENT PROCEDURE
FIGURE F.15 – EXCITER COVER REMOVAL
POLE PIECE BOLTS (4)
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F-46
EXITER FRAME
ARMATURE
BRUSH HOLDER
ASSEMBLY (2)
SLEEVE COLLAR
FLAT WASHER
ARMATURE LOCKING NUT
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EXITER COVER
PROCEDURE
DC Exciter Armature Removal Procedure
1. Turn the engine OFF.
2. Using the 3/8” nut driver, remove the exciter
cover. See Figure F.15.
3. Using the 3/8” wrench, remove the two brush
holder assemblies. Note insulator placement
for reassembly.
4. Bend the flat washer away from the armature
locking nut.
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5. Using the 1-5/8” socket wrench, remove the
armature locking nut, washer, and sleeve collar.
Reassembly:
7. Upon reassembly, the armature locking nut
should be torqued to 170 ft.-lbs. Install a
new sleeve collar if necessary (Part number
T5345). Bend the flat washer against the
locking nut.
8. Install the brush holder assemblies. Note
insulator placement.
9. Check the armature air gap. Minimum gap
should be .025”.
10. Install the exciter cover.
6. Carefully remove the armature by sliding it
from the shaft.
NOTE: The sleeve collar may have to be
removed with a gear puller. Be careful
not to damage the armature commutator.
PIPELINER® 200
F-46
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F-47
TROUBLESHOOTING & REPAIR
DC EXCITER ARMATURE & FIELD COILS
REMOVAL AND REPLACEMENT PROCEDURE
Field Coils Removal Procedure
1. Perform the DC Exciter Armature Removal
Procedure.
2. Using the 3/8” wrench, remove the leads from
the brush holder. Note lead placement for
reassembly.
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3. Using the 1/2” wrench, remove the four bolts
(two on each side) holding the pole pieces to
the exciter frame. See Figure F.15.
4. Label and remove the tape and splices from
the black and red leads that go to the idler
board and 115VDC receptacle. See the
Wiring Diagram.
Reassembly:
7. Assemble the new coils to their respective
pole pieces.
8. Assemble the coil and pole pieces to the
exciter frame with four bolts.
9. Make the necessary lead connections to the
idler board and 115VDC receptacle. Wrap
the slices with tape.
10. Assemble the armature and brushes.
See the DC Exciter Armature Removal
Procedure.
5. Carefully slide the coils and pole pieces from
the exciter frame.
6. Remove the coils from the pole pieces.
PIPELINER® 200
F-47
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F-48
NOTES
PIPELINER® 200
F-48
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F-49
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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
or 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 Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
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.
Return to Section TOC
F-49
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the main DC
generator frame.
MATERIALS NEEDED
Rope sling
Wood or steel blocks
Pry bars
9/16” Wrench
1/2” Wrench
7/16” Wrench
3/4” Wrench
Slot head screw driver
Wiring Diagram
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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F-50
F-50
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.16 – BATTERY PANEL REMOVAL
NEGATIVE
BATTERY
CABLE
PROCEDURE
1. Turn the engine OFF.
2. Using the 7/16” wrench, remove the two bolts
and washers and partially slide out the battery
mounting panel. See Figure F.16.
3. Using the 1/2” wrench, remove the negative
battery cable.
PIPELINER® 200
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F-51
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.17 – TOP AND DOORS ASSEMBLY DETAILS
BOLT / NUT (4)
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'L' DOOR
HOOKS (4)
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F-51
4. Using the 1/2” wrench, remove the four nuts
and bolts holding the case top and doors
assembly to the welder frame. Remove the
rubber gasket from the top. Carefully lift up
and remove the top and doors assembly.
Carefully remove the “L” shaped door hooks.
See Figure F.17.
PIPELINER® 200
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F-52
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.18 – FUEL TANK MOUNTING DETAILS
BOLTS / NUTS /
WASHERS (4)
FUEL LINE
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FUEL TANK
FUEL BOWL
RAILS
5. Perform the DC Exciter Armature Removal
Procedure.
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6. Turn off the fuel supply at the fuel bowl and
remove the fuel line. Plug the line to avoid
spillage.
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F-52
7. Using the 9/16” wrench, remove the four nuts,
bolts, and washers holding the fuel tank
assembly to the rails. See Figure F.18.
8. Carefully remove the fuel tank and set it aside
in a safe area.
PIPELINER® 200
TROUBLESHOOTING & REPAIR
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F-53
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.19 – SELECTOR SWITCH LEAD REMOVAL
SELECTOR
SWITCH
TERMINAL
C
A
B
D
E
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LEAD (5)
9. Using the 1/2” wrench, remove the five heavy
flex leads from the selector switch terminals.
Label the leads for reassembly. See Figure
F.19.
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FIGURE F.20 – OUTPUT TERMINAL LEAD REMOVAL
A
E
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D
B
C
POSITIVE OUTPUT
TERMINAL AND LEAD
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F-53
10. Using the 3/4” wrench, remove the copper
strap from the negative output terminal. See
Figure F.20.
11. Using the 3/4” wrench, remove the heavy
lead from the positive output terminal. See
Figure F. 20.
PIPELINER® 200
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F-54
TROUBLESHOOTING & REPAIR
F-54
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.21 – CHOKE CONTROL CABLE REMOVAL
CHOKE
CABLE
12. Using the slot head screw driver, remove the
choke control cable from the engine carburetor assembly. Mark cable replacement for
reassembly. See Figure F.21.
PIPELINER® 200
LOOSEN
HERE
TROUBLESHOOTING & REPAIR
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F-55
F-55
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.22 – FRONT PANEL WIRING CONNECTIONS
IDLER PC BOARD
IDLER SWITCH
D
B
C
START BUTTON
A
IGNITION SWITCH
LEADS TO AMMETER
E
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TO IDLER SWITCH
SHUNT LEADS
QUICK DISCONNECT
DC RECEPTACLE
13. Using the slot head screw driver, remove the
red lead connecting the 115VDC receptacle
to the DC exciter. See Figure F.22 and the
Wiring Diagram. Cut any necessary cable
ties.
14. Remove the leads connecting the idler PC
board to the DC exciter. See Figure F.22 and
the Wiring Diagram. Cut any necessary
cable ties.
15. Disconnect the blue and brown main shunt
leads from their quick disconnect splices.
See the Wiring Diagram.
18. Using the 3/8” nut driver, remove the leads
from the ammeter. Label for reassembly.
See Figure F.22 and the Wiring Diagram.
19. Label and remove the leads from the idler
switch. See Figure F.22 and the Wiring
Diagram.
20. Remove leads from the Idler Solenoid. See
Wiring Diagram.
16. Disconnect the leads from the START button
switch. See Figure F.22 and the Wiring
Diagram.
17. Remove the leads from the ignition switch.
Label for reassembly. See Figure F.22 and
the Wiring Diagram.
PIPELINER® 200
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F-56
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.23 – FRONT PANEL FASTENER REMOVAL
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BOLTS / NUTS / WASHERS (2)
MIDDLE SCREW (1)
BASE MOUNTING BOLTS (4)
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23. Using the 1/2” wrench, remove the two bolts,
nuts, and washers that hold the front panel
assembly to the horizontal rails. (There is
one on each side.) See Figure F.23.
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F-56
24. Using the 9/16” wrench, remove the four
bolts, nuts, and washers from the bottom of
the front panel assembly. These four bolts
mount the front to the base. (There are two
on each side.) See Figure F.23.
25. Using the 3/8” nut driver, remove the screw
from the lower middle of the front panel. See
Figure F.23.
26. Carefully remove the front panel assembly.
PIPELINER® 200
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F-57
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.24 – BRUSH BRACKET WRAP-AROUND COVER
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BRUSH BRACKET
REMOVE (2) NUTS,
WASHERS, AND SCREWS
WRAP- AROUND COVER
27. Using the slot head screw driver, remove the
two screws and nuts from the brush bracket
wrap-around cover. Remove the cover. See
Figure F.24.
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FIGURE F.25 – MAIN GENERATOR BRUSH BRACKET CLAMPING BOLT
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F-57
CLAMPING BOLT
BRUSHES (8)
BRUSH BRACKET
28. Lift the eight brushes from the main commutator. Note their positions for reassembly.
29. Using the 7/16” wrench, loosen (do not
remove) the main generator brush bracket
clamping bolt. Note the position of the drill
spot for reassembly. See Figure F.25.
PIPELINER® 200
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F-58
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.26 – MAIN GENERATOR FEET MOUNTING
FEET (2)
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MAIN GENERATOR
REMOVE MOUNTING
NUTS, WASHERS,
AND BOLTS
30. Using the 3/4” wrench, remove the frame
mounting bolts, nuts, and washers from the
feet of the main generator. See Figure F.26.
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FIGURE F.27 – MAIN GENERATOR ENGINE MOUNTING
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F-58
SLING
ENGINE / GENERATOR
MOUNTING HOLES
31. With the rope sling around the main generator frame, carefully lift the frame a small distance. Slide the wood or steel blocks under
the engine. See Figure F.27.
32. Using the 9/16” wrench, remove the bolts
and lock washers mounting the generator
frame to the engine. See Figure F.27.
PIPELINER® 200
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F-59
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
33. Using the rope sling and pry bars, carefully
lift and “wiggle” the generator frame away
from the engine and armature assembly. Be
careful to support the generator frame as
you remove it.
NOTE: The exciter frame is also removed with
the main generator frame.
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Reassembly: Refer to Figures F.26 & F.27 as
needed.
1. Using the rope sling, carefully lift and “wiggle”
the generator frame onto the engine and
armature assembly. Be careful to support the
generator frame as you position it.
2. Using the 9/16” wrench, install the bolts and
lock washers mounting the generator frame to
the engine. Using the 3/4” wrench, install the
frame mounting bolts, nuts, and washers to
the feet of the main generator. Check air gap
– min. .035” for main generator.
8. Carefully position the fuel tank to the mounting rails. Using the 9/16” wrench, install the
four nuts, bolts, and washers holding the fuel
tank assembly to the rails. Remove the plug
from the fuel line and attach it to the fuel bowl.
9. Perform the DC Exciter
Reassembly Procedure.
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11. Using the 1/2” wrench, install the negative
battery cable. Slide the battery mounting
panel back into place and, using the 7/16”
wrench, install the two bolts and washers
that secure the panel.
3. Using the 7/16” wrench, tighten the main generator brush bracket clamping bolt. Note the
position of the drill spot.
5. Using the slot head screw driver, install the
brush bracket wrap-around cover with two
nuts and screws.
6. Carefully set the front panel assembly into
position. Using the 3/8” nut driver, install the
screw for the lower middle of the front panel.
Using the 9/16” wrench, install the four bolts,
nuts, and washers for the bottom of the front
panel assembly. Then install the two bolts,
nuts, and washers that hold the front panel
assembly to the horizontal rails.
7. Reconnect all leads previously removed. See
the Wiring Diagram.
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Armature
10. Carefully set the top and doors assembly
into place. Install the “L” shaped door hooks.
Using the 1/2” wrench, install the four nuts
and bolts holding the case top and doors
assembly to the welder frame. Install the
rubber gasket to the top.
4. Install the eight brushes against the main
commutator. Observe the positions you noted
during disassembly.
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F-59
PIPELINER® 200
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F-60
NOTES
PIPELINER® 200
F-60
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F-61
TROUBLESHOOTING & REPAIR
MAIN GENERATOR ARMATURE
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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
or 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 Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
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.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the main armature.
MATERIALS NEEDED
Rope sling
5/8” Wrench
Wood or steel blocks
PIPELINER® 200
F-61
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F-62
TROUBLESHOOTING & REPAIR
F-62
MAIN GENERATOR ARMATURE
REMOVAL AND REPLACEMENT PROCEDURE
FIGURE F.28 – MAIN GENERATOR ARMATURE MOUNTING
SLING
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BLOWER PADDLE
MOUNTING BOLTS /
LOCK WASHERS (8)
PROCEDURE
1. Turn the engine OFF.
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2. Perform the DC Exciter Armature Removal
procedure.
3. Perform the Main
Removal procedure.
Generator
Frame
4. Using the rope sling, support the armature.
5. Make sure the engine supported with the
wood or steel blocks.
6. Using the 5/8” wrench, remove the eight bolts
and lock washers holding the blower paddles
and the armature to the engine flywheel. See
Figure F.28.
7. With the armature supported and “balanced”
in the rope sling, carefully rotate the armature
1/8 turn in either direction to release it.
CAUTION
Replacement: Refer to Figure F.28
1. Support the armature with the rope sling.
Mount the armature to the engine, rotating it
1/8 turn in either direction to achieve attachment. Before removing the rope sling, be
careful to support the armature with the wood
or steel blocks under the engine. With the
5/8” wrench, install the eight bolts and lock
washers that attach the blower paddles and
the armature to the engine flywheel.
2. Perform other replacement procedures
according to each of the following:
Generator
Frame
Replacement
DC Exciter Armature
Replacement
The armature is now free to be removed from
the engine.
PIPELINER® 200
Removal
Removal
and
and
TROUBLESHOOTING & REPAIR
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F-63
F-63
RETEST AFTER REPAIR
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machineʼs electrical characteristics.
OR
• If you repair or replace any electrical components.
Engine
Perkins
Perkins
Kubota
Kubota
GM (Gas)
GM (Gas)
Mode
Low Idle
High Idle
Low Idle
High Idle
Low Idle
High Idle
ENGINE OUTPUT
No Load RPM
1375-1425
1540-1650
1390-1410
1580-1600
1340-1360
1580-1600
WELDER DC OUTPUT
Current Control
Rheostat
Maximum
Current Selector
Switch
Maximum
Open Circuit
Voltage
88-98
Load RPM
NA
1450-1600
NA
1550-1600
NA
1550-1600
Load Volts
33-39
DC AUXILIARY POWER RECEPTACLE OUTPUT
Open Circuit Voltage
124-138
Exciter DC Volts
123 - 137
Load Volts
115-130
FIELD AMPS AND VOLTS
(Current Rheostat at Maximum)
Main Shunt Field Amps
2.10-2.70
PIPELINER® 200
Load Amps
300
Load Amps
15.0
RPM
1540-1600
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F-64
NOTES
PIPELINER 200
F-64
TABLE OF CONTENTS - DIAGRAM SECTION
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G-1
G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - Code 10660 - (L11402) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram - Code 10913, 11136 - (L11864) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram - Code 10929 - (M20056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram - Code 11114, 11316 - (M20464) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Schematic – Complete Machine - Code 10929 - (L12020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Schematic – Complete Machine - Code 11114. 11316 - (L12362) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
Schematic – Complete Machine - Code 11471 - (L13350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9
Schematic – Current Sense PC Board - Code 10929, 11114, 11316, 11471 - (S25973) . . . . . . . . . . . . .G-10
Schematic – Idler / Engine Shutdown - Code 10929 - (L10826) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
* NOTE:
Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered and are therefore considered to be unserviceable. Assembly drawings of these boards are
no longer provided.
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Wiring Diagram - Code 11471 - (M21564) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
PIPELINER 200
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G-2
WIRING DIAGRAM - CODE 10660 - (L11402)
PIPELINER 200G WIRING DIAGRAM
INJECTOR
72
90
91
#
+
97
-
97B
97A
A
71
B
COIL
83
- +
Return to Master TOC
PARTS SUPPLIED
WITH ENGINE
Return to Section TOC
1
A B
WATER
TEMP.
SENSOR
93
95
61
60
74
IGNITION
SWITCH
G
73
S
+
67
42
602A
RHEOSTAT
600A
GENERATOR
45
OIL PRESS. G
GAUGE
SEE
*BELOW
B
R
NEGATIVE
(CC-)
WIRE FEED MODULE (OPTIONAL)
41
600
42
602
Y
W
P8
SWITCH FOR LOCAL OR REMOTE CONTROL
SHOWN IN LOCAL POSITION.
PLUG FOR
REMOTE CONTROL
POTENTIOMETER
12 11 10 9 8 7 6 5 4 3 2 1
P11 * * SEE BELOW
X
CAUTION: DAMAGE CAN OCCUR
TO THE REMOTE CONTROL
SWITCH IF IT IS USED
WITHOUT THE "P11" PLUG
INSTALLED OR A WIRE
FEED MODULE INSTALLED.
RESISTORS
REMOTE CONTROL
POTENTIOMETER BOX
WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8".
* THEN
CONNECT PLUG "P8" ON REMOTE CONTROL TO CONNECTOR "J8" ON MACHINE.
F A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE
** IUNCONNECTED
PLUG "P10" (IF ONE IS ON THE MACHINE) FASTEN THE NEW PLUG "P11"
NEARBY, LEAVING IT UNCONNECTED.
IF NO WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISCONNECT PLUG "P10"
ON THE MACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM THE REMOTE CONTROL
KIT TO CONNECTOR "J5" ON THE MACHINE.
CAUTION: DAMAGE CAN OCCUR TO THE REMOTE CONTROL SWITCH IF IT IS USED
WITHOUT THE "P11" PLUG INSTALLED OR A WIRE FEED MODULE INSTALLED.
ON PIPELINER 200G MACHINES, CONNECT RED AND BLACK LEADS ON REMOTE TO
RED AND BLACK LEADS ON MACHINE.
5 4 3 21
WELDER
LEAD BLOCK
N
CURRENT
SENSOR
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN THE SAME (CURRENT FLOW)
DIRECTION AS SHOWN.
X
Y
G
CONNECT
TO CASE B
W
U
POSITIVE
(CC+) & (CV+ WITH W.F.M.)
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
REMOTE CONTROL RECEPTACLE & SWITCH
1
2
3
4
5
6
A
4
3
2
1
80
K924-4 REMOTE CONTROL (OPTIONAL)
SEE
*BELOW
J8
P9
SELECTOR
SWITCH
B
GROUND
TO BASE
GROUND
TO ENGINE
1
2
3
4
5
6
610B
S
Return to Master TOC
41
W
U
602B
IDLER
SWITCH
99
R
610
600B
69
S
70
N
E
B
SWITCH
SENSOR
WATER TEMP.
GAUGE
STARTER
MOTOR
WK
WATER TEMP. SENDER
12 11 10 9 8 7 6 5 4 3 2 1
RECEPTACLE
SENSOR
51
84
FOR
REMOTE
OPTION
OIL PRESSURE SWITCH & SENSOR
AMMETER
62
AIR
TEMP.
SENSOR
99E
87A
78
89
CB5
A B
76
J5
TO
EXCITER R
OUTPUT
99C
99B
P10
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAME
NEUTRE RACCORDE' AU BATI
E
-
MAP SENSOR
ENGINE
FAILURE
LAMP
-
+
99D
A B C
ENGINE
HOUR METER
87B
77
94
DISTRIBUTOR
CONTROL PA NEL
GROU ND SCR EW
Return to Master TOC
3
2
87
82
+ EXC
-
Return to Section TOC
3
2
50
99A
96
ALTERNATOR
97C
B
10 K
1
81
THROTTLE PLATE
MOTOR
START
ELECTRICAL SYMBOLS
PER E1537
LEAD COLOR CODE
B - BLACK
G - GREEN
N - BROWN
4
R - RED
U - BLUE
W - WHITE
Y - YELLOW
+
RPM CONTROL
ZENITH THROTTLE
3
BODY
4
CONTROLLER
5
14 WHITE
15 CONNECTOR
19
21
BLACK
22
CONNECTOR
1 2 3 4 5 8 9 11 12 13 17
92
FUEL PUMP
Return to Section TOC
G-2
ELECTRICAL DIAGRAMS
INLINE
CONNECTORS
PLUG
(P5)
W.F.M.
CONTROL
PANEL
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
NEGATIVE CV
OUTPUT TERMINAL
PANEL
{
CONNECT TO NEG.
BRUSH HOLDER
200 AMP
THERMOSTAT
ASSEMBLY
POS.
NEG.
#8 LEAD
#2 HEAVY LEAD
608
WIRE FEED
MODULE
609
#2 HEAVY LEAD
MACHINE MUST NOT BE RUNNING
WHEN MAKING THESE CONNECTIONS.
A
L11402
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
PIPELINER® 200
Return to Master TOC
Return to Section TOC
G-3
WIRING DIAGRAM - CODE 10913, 11136 - (L11864)
PIPELINER 200G WIRING DIAGRAM
INJECTOR
72
90
91
97
-
97B
FUEL PUMP
97A
THROTTLE PLATE
MOTOR
71
B
COIL
83
Return to Master TOC
Return to Section TOC
PARTS SUPPLIED
WITH ENGINE
1
A B
WATER
TEMP.
SENSOR
99B
93
95
60
AMMETER
74
62
IGNITION
SWITCH
51
99E
J5
N
U
GROUND
TO ENGINE
41
42
B
602A
RHEOSTAT
600A
IDLER
SWITCH
5 4 3 21
WELDER
LEAD BLOCK
N
CURRENT
SENSOR
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN THE SAME
(CURRENT FLOW) DIRECTION AS SHOWN.
NEGATIVE
(CC-)
K924-5 REMOTE CONTROL (OPTIONAL)
RESISTORS
REMOTE CONTROL
POTENTIOMETER BOX
B
W
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION.
U
POSITIVE
(CC+) & (CV+ WITH W.F.M.)
WIRE FEED MODULE (OPTIONAL)
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
INLINE
CONNECTORS
X PLUG FOR
REMOTE CONTROL
POTENTIOMETER
W
A
4
3
2
1
GROUND
TO BASE
CONNECT
TO CASE
P8
J8
SELECTOR
SWITCH
Y
GENERATOR
610B
80
G
G
41
600
42
602
SWITCH
45
Y
1
2
3
4
5
6
R
W
X
602B
B
99
R
OIL PRESS.
GAUGE
610
600B
E
69
S
70
87A
B
R
-E
R
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAME
NEUTRE RACCORDE' AU BATI
12 11 10 9 8 7 6 5 4 3 2 1
RECEPTACLE
SENSOR
S
+
WK
WATER TEMP. SENDER
WATER TEMP.
GAUGE
STARTER
MOTOR
AIR
TEMP.
SENSOR
76
SENSOR
G
73
84
A B
S
Return to Master TOC
4
TO
EXCITER
OUTPUT
OIL PRESSURE SWITCH & SENSOR
67
Return to Master TOC
3
P10
78
89
CB5
77
99C
MAP SENSOR
ENGINE
FAILURE
LAMP
-
61
+
99D
A B C
CONTROL PANEL
GROUND SCREW
Return to Section TOC
2
87B
94
DISTRIBUTOR
ENGINE
HOUR METER
B
3
2
87
82
+ EXC
-
START
1
50
99A
96
ALTERNATOR
97C
+
10 K
81
A
- +
+
ELECTRICAL SYMBOLS
PER E1537
LEAD COLOR CODE
B - BLACK OR U - BLUE
GRAY
W - WHITE
G - GREEN
Y - YELLOW
R - RED OR
PINK
RPM CONTROL
ZENITH THROTTLE
3
BODY
4
CONTROLLER
5
WHITE
14
15 CONNECTOR
19
21
BLACK
22
CONNECTOR
1 2 3 4 5 8 9 11 12 13 17
92
#
Return to Section TOC
G-3
ELECTRICAL DIAGRAMS
PLUG
(P5)
W.F.M.
CONTROL
PANEL
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
NEGATIVE CV
OUTPUT TERMINAL
PANEL
{
CONNECT TO NEG.
BRUSH HOLDER
200 AMP
THERMOSTAT
ASSEMBLY
#8 LEAD
POS.
NEG.
#2 HEAVY LEAD
608
WIRE FEED
MODULE
609
#2 HEAVY LEAD
*
MACHINE MUST NOT BE RUNNING
WHEN MAKING THESE CONNECTIONS.
B
L11864
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
PIPELINER® 200
WIRING DIAGRAM - CODE 10929 - (M20056)
PIPELINER 200D WIRING DIAGRAM
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODE
GLOW PLUGS
61
EXCITER BRUSHES SHOWN AS
VIEWED FROM CONTROL PANEL
1 2 3 4 5 6 7 8 9 10
IDLER / ENGINE
J1 PROTECTION J2
P.C. BOARD
58
60C
53B
57
56A
+IGNITION
SWITCH
58A
52
50B
IDLER
SOLENOID
56
SHUNT
N
600B
-
U
610
602B
+
830
70
IDLER
SWITCH
730A
54
RHEOSTAT
58H
600A
761
820
I
59
50
OIL
PRESSURE
GAUGE
G
GENERATOR LEAD BLOCK
SHOWN AS VIEWED WITH
ENGINE IN THIS DIRECTION
GND-M
67C
+
+
-
INTERPOLE
NEGATIVE
(CC-)
POSITIVE
(CC+) & (CV+ WITH W.F.M.)
GROUND SCREW NEAR ENGINE GUAGES
N
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN SAME (CURRENT FLOW)
DIRECTION AS SHOWN.
ON MACHINE, REMOVE PLUG "P10 FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
INLINE
CONNECTORS
X PLUG FOR
REMOTE CONTROL
POTENTIOMETER
Y
G
B
W
U
WIRE FEED MODULE (OPTIONAL)
K924-5 REMOTE CONTROL (OPTIONAL)
CONNECT
TO CASE
-
SERIES
+ EXC
200
GROUND GROUND
TO
TO BASE
ENGINE
R
A
51
51G
Y
W
SHUNT
212B
ALTERNATOR
I
S
CURRENT 840
SENSOR
4
844
3 J3
842
2
1
841
600
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION
SELECTOR
SWITCH
3
AMMETER
-
+
+
WK
OIL PRESSURE
SWITCH/SENDER
G
G
730B
67D
2
S
TEMPERATURE
GAUGE
F1
15A
W
TEMPERATURE
SWITCH/ SENDER
41
1
2
X
3
4
42
5
602
6
W
J8 P9
1
54D
STARTING
MOTOR
42
602A
54B
G
60
41
GND-T
GROUND SCREW NEAR FUSE
720A
FUEL PUMP
S
720B
SERIES
PUMP SOLENOID GND-B
212A
51A
50A
B
Return to Master TOC
12 11 10 9 8 7 6 5 4 3 2 1
5
ENGINE
HOUR
START METER
G
GND-N
PLUG (P5)
W.F.M.
CONTROL
PANEL
#8 LEAD
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
NEGATIVE CV
OUTPUT TERMINAL
PANEL
RESISTORS
Return to Master TOC
J5
4
Return to Master TOC
GLOW
PLUG
Return to Section TOC
P10
RECEPTACLE
53
Return to Section TOC
1
2
3
4
R
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
B-BLACK OR R-RED OR
PINK
GRAY
U-BLUE
G-GREEN
W-WHITE
N-BROWN
Y-YELLOW
60A
ENGINE
FAILURE
LAMP
Return to Section TOC
G-4
ELECTRICAL DIAGRAMS
610B
Return to Master TOC
Return to Section TOC
G-4
WIRE FEED
MODULE
POS.
NEG.
#2 HEAVY LEAD
608
CONNECT TO NEG.
BRUSH HOLDER
609
#2 HEAVY LEAD
250 AMP THERMOSTAT ASSEMBLY
REMOTE CONTROL
POTENTIOMETER BOX
MACHINE MUST NOT BE RUNNING
* WHEN
MAKING THESE CONNECTIONS.
B
M20056
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
PIPELINER® 200
WIRING DIAGRAM - CODE 11114, 11316 - (M20464)
PIPELINER 200D WIRING DIAGRAM
NOTE: LEAD 70A IS LEFT
OPEN AND WIRE
TIED INTO HARNESS.
212C
55 *
53
51A
GND-M
STARTING
S MOTOR
+-
50
Return to Master TOC
BATTERY
GROUND
TO
BASE
GROUND * 60E
TO * 60F
ENGINE
G
WK
G
B
W
RESISTORS
REMOTE CONTOL
POTENTIOMETER BOX
CONNECT TO CASE
70C
730A
RPM CONTROL
GND-T
720B
70B*
41
42
602A
RHEOSTAT
600A
GROUND SCREW NEAR FUSE
720A
720C
G
1
2
3
*87 *86 * 88
610C
F1
15A
610D
200
PLUG FOR REMOTE CONTROL
POTENTIOMETER
X
RECEPTACLE
600C
U
602B
+
SERIES
K924-5 REMOTE CONTROL (OPTIONAL)
Y
Return to Master TOC
58 *
610
G
41
1
600
2
Y
X
3
4
42
W
5
R
6 602
W
J8 P9
730B
67B
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION
SELECTOR
SWITCH
GENERATOR LEAD BLOCK
SHOWN AS VIEWED WITH
ENGINE IN THIS DIRECTION
1
3
4
2
SERIES
3 TURNS
-
+
+
-
67A
NEGATIVE
(CC-)
SHUNT
*64
51
212E
-
S I
OIL
G
841
PRESSURE
GAUGE
ALTERNATOR
WATER
ENGINE
TEMP.
SPEED
L
SENSOR
SENSOR
B
IG
69
94
*
*
93
* 844A
60
*
60A
GND-B
844
842
IDLER SWITCH
GROUND SCREW NEAR
ENGINE GAUGES
*54
AMMETER
+
B
43
841
WATER
841B TEMP
GAUGE
S
I
OIL PRES.
SWITCH/
SENDER
51C
50A
Return to Section TOC
*
+ -
212A
62
GLOW
PLUG
TEMP.
SWITCH/
SENDER
W
G
*44
IGNITION
SWITCH
51B
600B
1
52A
* 212D
841A
N
SHUNT
ACTUATOR
GND-N
Return to Master TOC
Return to Section TOC
START RELAY
* 61
P10
12 11 10 9 8 7 6 5 4 3 2 1
J5
4 2
* 57
* 56
EXCITER BRUSHES SHOWN AS
VIEWED FROM CONTROL PANEL
ENGINE
FAILURE
ENGINE HOUR METER
LAMP
WIRE-TIED TO WIRING
HARNESS BEHIND
CONTROL PANEL
* 52B
NEUTRAL BONDED TO FRAME.
NEUTRE RACCORDE' AU BATI.
A
70B
844A
70A
94
44
60E
54
64
LEAD COLOR CODE
B-BLACK OR R-RED OR
GRAY
PINK
G-GREEN
U-BLUE
N-BROWN
W-WHITE
Y-YELLOW
610B
57
212B
GLOW PLUGS
*
9
17
25
34
61
93
51B
212D 55
58
69
52B
87 88
56 86
60F
CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
LEADS CONNECTED TO ENGINE CONTROL UNIT, SEE DETAIL
5 3
ENGINE CONTROL UNIT CONNECTOR DETAIL
START
Return to Section TOC
G-5
ELECTRICAL DIAGRAMS
1
10
18
26
Return to Master TOC
Return to Section TOC
G-5
INTERPOLE
POSITIVE
(CC+) & (CV+ WITH W.F.M.)
N
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN SAME (CURRENT FLOW)
DIRECTION AS SHOWN.
U
WIRE FEED MODULE (OPTIONAL)
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
INLINE CONNECTORS
W.F.M.
CONTROL
PANEL
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
NEGATIVE CV
OUTPUT TERMINAL
PANEL
CONNECT TO NEG.
BRUSH HOLDER
PLUG P5
POS.
NEG.
608
#8 LEAD
#2 HEAVY LEAD
WIRE FEED
MODULE
609
#2 HEAVY LEAD
250 AMP THERMOSTAT ASSEMBLY
MACHINE MUST NOT BE RUNNING
WHEN MAKING THESE CONNECTIONS.
A
M20464
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
PIPELINER® 200
WIRING DIAGRAM - CODE 11471 - (M21564)
PIPELINER 200D WIRING DIAGRAM
ENGINE CONTROL UNIT CONNECTOR DETAIL
61
93
51B
212D 55
58
69
52B
88
87
56 86
60F
9
17
25
34
Return to Master TOC
Return to Master TOC
G-6
ELECTRICAL DIAGRAMS
57
CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
LEADS CONNECTED TO ENGINE CONTROL UNIT, SEE DETAIL
LEAD COLOR CODE
B-BLACK OR R-RED OR
GRAY
PINK
G-GREEN
U-BLUE
N-BROWN
W-WHITE
Y-YELLOW
*
NOTE: LEAD 70A IS LEFT
70B
OPEN AND WIRE
844A
TIED INTO HARNESS.
70A
EXCITER BRUSHES SHOWN AS
P10
94
12 11 10 9 8 7 6 5 4 3 2 1
VIEWED FROM CONTROL PANEL
44
60E
J5
57
54
*
ACTUATOR
64
*56
N
ENGINE
SHUNT
U
FAILURE
600B
ENGINE HOUR METER
610
LAMP
WIRE-TIED TO WIRING
602B
+
+
HARNESS BEHIND
START
841A
58 *
61
*
RECEPTACLE
CONTROL PANEL
600C
720B
841
SERIES
70C
70B*
*52B
START RELAY
G
TEMP. SWITCH
41
41
1
GND-T
* 212D
600
RPM CONTROL
2
52A
212C
44
IGNITION
*
841B
Y
X
3
42
GROUND SCREW NEAR FUSE
55 *
SWITCH
WATER
4
602A
53
720A
TEMP. SENDER S
42
W
I TEMP
51B *
5
RHEOSTAT
720C
43
R
602
6
GAUGE
600A
W
J8 P9
G
62
GLOW
212A
1
2
3
F1
PLUG
51A
OIL PRES.
15A
730B
*87 *86 * 88
SWITCH/
67B
51C
SWITCH FOR LOCAL OR
SENDER
SELECTOR
610D
REMOTE CONTROL SHOWN
50A
I
S
SWITCH
IN LOCAL POSITION
200
2 TURNS
*54
OIL
STARTING
G
WK
AMMETER
GENERATOR LEAD BLOCK
G
841
1
SHOWN AS VIEWED WITH
PRESSURE
S MOTOR
3
ENGINE IN THIS DIRECTION
GAUGE
4
B
50
ALTERNATOR
2
WATER
SERIES
ENGINE
+
TEMP.
SPEED
L
64
3
TURNS
* 51
SENSOR
SENSOR
+
B
BATTERY
IG
69
94
*
*
844A
*
60
INTERPOLE
*93
67A
60A
GND-B
844
GROUND * 60E
NEGATIVE POSITIVE
GROUND
842
* 60F
(CC+) & (CV+ WITH W.F.M.)
TO
(CC-)
TO
IDLER SWITCH
GROUND SCREW NEAR
ENGINE
THESE LEADS MUST BE ROUTED THRU
BASE
N
CURRENT SENSOR IN SAME (CURRENT FLOW)
U
ENGINE GAUGES
GLOW PLUGS
610B
GND-M
5 3
A
4 2
1
212E
+
Return to Master TOC
DIRECTION AS SHOWN.
K924-5 REMOTE CONTROL (OPTIONAL)
PLUG FOR REMOTE CONTROL
POTENTIOMETER
G
X
B
W
RESISTORS
Return to Master TOC
SHUNT
Return to Section TOC
+-
Y
Return to Section TOC
212B
GND-N
610C
730A
1
10
18
26
Return to Section TOC
Return to Section TOC
G-6
REMOTE CONTOL
POTENTIOMETER BOX
CONNECT TO CASE
WIRE FEED MODULE (OPTIONAL)
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
INLINE CONNECTORS
W.F.M.
CONTROL
PANEL
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
NEGATIVE CV
OUTPUT TERMINAL
PANEL
CONNECT TO NEG.
BRUSH HOLDER
PLUG P5
POS.
NEG.
608
#8 LEAD
#2 HEAVY LEAD
WIRE FEED
MODULE
609
#2 HEAVY LEAD
250 AMP THERMOSTAT ASSEMBLY
MACHINE MUST NOT BE RUNNING
WHEN MAKING THESE CONNECTIONS.
B
M21564PRINT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
PIPELINER® 200
Return to Master TOC
SCHEMATIC -COMPLETE MACHINE - CODE 10929 - (L12020)
ENGINEERING CONTROLLED
MANUFACTURER: No
J2-1
J2-2
J2-3
J2-4
J2 CONNECTOR IS NOT
USED ON THIS MACHINE
LEFT SIDEOF ENGINE(ASVIEWED
FROM CONTROL PANEL)
HOUR METER
CR1
N.O.
ENGINE
RUNNING
J1-5
Q2
70
R
I
G
TEMPERATURE
GAUGE
-
SERIES FIELD
JUMPER PLUG IS FOR
CONNECTION TO WIRE
FEED MODULE
12 11 10 9 8 7 6 5 4 3 2 1
J5
DC EXCITER USES RESIDUAL
MAGNETISM TO FLASH
RHEOSTAT
64+/-6.4 OHMS MAX
CCW
REMOTE CONTROL BOX
FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
P10
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
RHEOSTAT
BATTERY
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
STARTER
MOTOR
+
CCW
64+/-6.4 OHMS MAX
+
START SWITCH
FDW-5M EXCITER COIL:
SHUNT COIL WINDINGS ARE 65+/-1.5 OHMS EACH
SERIES COIL WINDINGS ARE .143 +/-.005 OHMS EACH
SHUNT FIELD
25+/-1.25 OHMS EACH
W
BACK OF MACHINE
(ASVIEWED FROM
CONTROL PANEL)
STARTER
SOLENOID
52
DC EXCITER
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
X
50
50A
OIL PRESSURE SWITCH / SENDER
SWITCH CLOSES
SENDER OPERATION:
0 PSI -> 10+/-5 OHMS
AT 6+/-2 PSI
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
IDLER DELAY TIMER CIRUITS
Q2 ON FOR HIGH IDLE
UPON RECIEVEING POWER,
CIRCUIT TO FLASH
ALTERNATOR IS OPENED AND
ENGINE PROTECTION IS
BYPASSED. AFTER TIME
DELAY, ALTERNATOR FLASHING
CIRCUIT IS CLOSED AND
ENGINE PORECTION IS
ENABLED. NOTE: AFTER TIME
DELAY WHEN ENGINE
PROTECTION IS ENABLED, IF
THE ENGINE IS NOT STARTED
THE OIL PRESSURE WILL BE
LOW AND THE MACHINE WILL
SHUT DOWN BECAUSE OF THE
ENGINE PROTECTION CIRCUIT.
G
S
Y
GLOW PLUGS
TYPICAL CURRENT DRAW
IS 40 +/- 3 AMPS
-
+
TEMPERATURE SWITCH / SENDER
SWITCH CLOSES
SENDER OPERATION: 212B
AT 230v+/-6vF
140vF -> 134+/-13.5 OHMS
SENDER IS APPROX.
194vF -> 51.2+/-4.3 OHMS
500 OHMS AT 70vF
212vF -> 38.5+/-3 OHMS
S
200
I OIL PRESSURE
54
GAUGE
WK
G
G
J1-7
ENGINE PROTECTION AND
ALTERNATOR FLASHING DELAY
TIMER LOGIC
54D
54B
W
J1-10
58A
51A
IGNITION
SWITCH SHOWN IN "OFF"
POSITION
212A
53B
J1-6
ENGINE
PROTECTION
AND
ALTERNATOR
FLASHING
DELAY TIMER
(SEE BELOW
FOR LOGIC)
-40 TO 40 AMPS
AMMETER
51G
56A
REMOTE CONTROL PLUG
G
50B
51
56
57
CR1
NO OVER
CURRENT
PROTECTION
+
J1-8
J1-2
J1-1
53
FLASH
BAT
BAT
8.8+/-.88 OHMS
TYPICAL CURRENT
DRAW IS 1.25 AMPS
IDLE
SOLENOID
FLYBACK DIODE
ENGINE
N.C. SHUTDOWN
58H
FUEL PUMP
TYPICAL CURRENT
DRAW IS .56 AMPS
3 AMP CURRENT LIMIT
K924-5 REMOTE CONTROL
(OPTIONAL)
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
GLOW PLUG
SWITCH
ALTERNATOR
55 AMP / 12 VOLT
59
J1-3
USED FOR TOROID IN AC
AUXILIARY MACHINES
J1-9
58
TYPICAL CURRENT
DRAW IS .98 AMPS
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
SCHEMATIC L10826
UNUSED
J1-4
61
INJECTION
PUMP
SOLENOID
Return to Master TOC
CHANGE DETAIL: Released A.01 from "X"
IDLER / ENGINE PROTECTION PC BOARD
RED ENGINE
PROTECTION
LIGHT
12 VOLT - NORMALLY OFF
Return to Section TOC
G-7
ELECTRICAL DIAGRAMS
L12020
Return to Section TOC
G-7
JUMPER PLUG IS
WIRE-TIED UPBEHIND
LOCAL / REMOTE
SWITCH ON RIGHT
SIDEOF MACHINE (AS
VIEWED FROM
CONTROL PANEL)
602B
DC AUXILIARY
RECEPTACLE
Return to Master TOC
Return to Section TOC
J8
844
P9
6
4 5
3
1
841
W
LOCAL / REMOTE
SWITCH
130
SERIES FIELD
SELECTOR SWITCH
90-MIN
130-80
190-120
240-160
220-MAX
DRIVER
CIRCUITS
J3-2
U
N
SHOWN IN LOCAL
POSITION
1 TURN
CURRENT SENSING PC BOARD
12 VOLT SUPPLY
X
REMOTE
RECEPTACLE
GENERATOR LEAD BLOCK
SHOWN AS VIEWED WITH
ENGINE IN THIS DIRECTION
SENSOR GROUNDS LEAD TO
IDLER / ENGINE PROTECTION
BOARD ON SENSE OF WELD OR
AUXILIARY LOAD
J3-4
J3-1
J3-3
720
FUSE
15 AMP
LOCATED BEHIND UPPER
PORTION OF CONTROL PANEL
JUMPER PLUG IS
WIRE-TIED UPBEHIND
LOCAL / REMOTE
Y SWITCH ON RIGHT
SIDEOF MACHINE (AS
VIEWED FROM
CONTROL PANEL)
G
602
761
2
-
+
+
-
SHUNT
FIELD FJW-5AR COIL PAIR:
22.5+/-.5 OHMS EACH
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
INTERPOLE
COILS
Return to Master TOC
Return to Section TOC
3 TURNS
THESE LEADS MUST BE ROUTED
THRU CURRENT SENSOR IN
SAME (CURRENT FLOW) DIRECTION
AS SHOWN
WELDING
GENERATOR
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
67
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2
6
LABELS:
COMMON
7
_
NEGATIVE OUTPUT TERMINAL
12
FRAME GROUND
+
POSITIVE OUTPUT TERMINAL
TYPICAL OCV (WARM MACHINE):
88-98 VOLTS AT MAX RHEOSTAT
47-60 VOLTS AT MIN RHEOSTAT
EARTH GROUND
LATCH
VIEW OF CONNECTOR ON PC BOARD
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
L11946
SCALE:
SUBJECT:
NA
MATERIAL
DISPOSITION:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
JRS
JRS
UF
PIPELINER 200D
MACHINE SCHEMATIC
APPROVAL
DATE:
12/09/2002
PROJECT
NUMBER:
CRM33528
1
1 OF ___
PAGE ___
DOCUMENT
REVISION:
DOCUMENT
NUMBER:
L12020
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PIPELINER® 200
Return to Master TOC
SCHEMATIC - COMPLETE MACHINE - CODE 11114, 11316 - (L12362)
Return to Master TOC
CHANGE DETAIL: Released A.02 from X
ENGINEERING CONTROLLED
MANUFACTURER: No
JUMPER PLUG IS BEHIND LOWER
RIGHTSIDE OFCONTROL PANEL
ENGINE
SPEED
SENSOR
BACK, RIGHT
SIDE OF ENGINE
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
SENSOR OPERATION:
-4vF -> 18.80 kOHMS
104vF -> 1.14 kOHMS
212vF -> .16 kOHMS
Return to Section TOC
G-8
ELECTRICAL DIAGRAMS
L12362
Return to Section TOC
G-8
94
20
93
17
12 VOLT SUPPLY
60A
69
WATER
TEMP.
SENSOR
BACK, LEFT
SIDE OF ENGINE
11
87
1
ENGINE CONTROL UNIT (ECU)
2
86
2
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
RATED VOLTAGE: 12V
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
3
88
3
10,000 +/- 1,000 OHMS MAX
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
BACK, LEFT SIDE OF ENGINE
ALTERNATOR
40 AMP / 12 VOLT
L
CCW
4
26
13
LOWER RIGHT OFCONTROL PANEL
RPM CONTROL POTENTIOMETER
64
SENSES ALTERNATOR OUTPUT
FLASHES ALTERNATOR
16
60
RATED VOLTAGE: 12V
RATED CURRENT: 2A
COIL RESISTENCE:
2.8 +/- .28 OHMS AT 20vC
ENERGIZED FOR RUN
ACTUATOR
DE-ENERGIZED FOR STOP
ACTUATOR CONTROLS RPM
BACK, RIGHT
MECHANICAL STOP WILL SHUT SIDE OF ENGINE
DOWN THE ENGINE AT 115%
OF RATED SPEED.
ENGINE
COLOR: RED
PROTECTION
12 VOLT
LIGHT
NORMALLY OFF
CENTER OF
841A
CONTROL PANEL
HOUR METER
CENTER OF
CONTROL PANEL
57
34
12 VOLT
SUPPLY
ECU CONNECTOR DETAIL
58
9
6
31
841B
THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE
PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT
DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
27
1
12
19
60F 60E
844A
30
7
32
CONNECT TO
CONNECT TO
GROUND FOR 70A
70B GROUND FOR
800RPM
1600RPM, LEAVE
OPEN LEAD IS WIRE-TIED INSIDE THE 70C UNCONNECTED
FOR 1800RPM
HARNESS BEHIND CONTROL PANEL
DC EXCITER
GND-B
DC EXCITER USES RESIDUAL
MAGNETISM TO FLASH
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
SHUNT FIELD
-
212E
43
Return to Master TOC
Return to Section TOC
844
-
+
212A
S
I
START
BUTTON
212C
52A
WIRE-TIED TO HARNESS
BEHIND CONTROL PANEL
THE P10 PLUG IS ONLY ON UNITS WITHOUT
THE WIRE FEED MODULE. THE WIRE FEED
MODULE HAS A HARNESS THAT PLUGS
DIRECTLY INTO J5.
842
DC AUXILIARY
RECEPTACLE
GND-T
610B
SCHEMATIC S25973
602A
12 11 10 9 8 7 6 5 4 3 2 1
4 6
1
2
G
602
720A
720C
610D
3
P9
LOWER LEFT OFCONTROL PANEL
DRIVER
CIRCUITS
ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED
FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING
720B
X
FUSE
15 AMP
REMOTE
RECEPTACLE
W
730B
SECOND
SERIES FIELD
SELECTOR SWITCH
90-MIN
130-80
190-120
240-160
220-MAX
BROKEN OR LOOSE BELT - INSPECT
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
HIGH WATER TEMPERATURE DETECTED FOR 1
SHOWN IN LOCAL
POSITION
0 RPM IS DETECTED AND 12V IS DETECTED
FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
FROM "L" TERMINAL ON ALTERNATOR
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
0 VOLTS DETECTED FROM "L" TERMINAL ON
ALTERNATOR FOR 1 SECOND
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
LONG 2, SHORT 8
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
+
+
-
U
SHUNT
FIELD FJW-5AR COIL PAIR:
22.5+/-.5 OHMS EACH
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
67A
_
WELDING
GENERATOR
+
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1 2
6
LABELS:
NEGATIVE OUTPUT TERMINAL
POSITIVE OUTPUT TERMINAL
TYPICAL OCV (WARM MACHINE):
88-98 VOLTS AT MAX RHEOSTAT
47-60 VOLTS AT MIN RHEOSTAT
UNDER LEFT DOOR
COMMON
7
12
FRAME GROUND
EARTH GROUND
LATCH
VIEW OF CONNECTOR ON PC BOARD
INCORRECT BATTERY - INSPECT
PROPRIETARY &
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
FAULTY ALTERNATOR - CHECK
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
SUBJECT:
ENGINEER:
L12020
SCALE:
DO NOT SCALE THIS DRAWING
APPROVED:
NA
MATERIAL
DISPOSITION:
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
ACTUATOR SENSED BY ECU
N
BROKEN OR LOOSE BELT - INSPECT
FAULTY ALTERNATOR - CHECK
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
U
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT 6
-
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
N
INTERPOLE
COILS
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT 1
JUMPER PLUG IS
WIRE-TIED UP BEHIND
LOCAL / REMOTE
Y SWITCH ON RIGHT
SIDE OF MACHINE
LOCAL / REMOTE
SWITCH
GENERATOR LEAD BLOCK
SHOWN AS VIEWED WITH
ENGINE IN THIS DIRECTION
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
"L" TERMINAL IS GROUNDED ON ALTERNATOR
602B
41
42
POSSIBLE CAUSE - CORRECTIVE MEASURE
LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM)
FOR 1 SECOND
JUMPER PLUG IS
WIRE-TIED UP BEHIND
LOCAL / REMOTE
SWITCH ON RIGHT
SIDE OF MACHINE (AS
VIEWED FROM
CONTROL PANEL)
J5
J8
J3-2
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND
LONG 1, SHORT 4
Return to Master TOC
P10
67B
LONG 1, SHORT 3
FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
RHEOSTAT
64+/-6.4 OHMS MAX
CCW
730A
5
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN SAME (CURRENT
FLOW) DIRECTION AS SHOWN
3 TURNS
FAILURE DETECTED
REMOTE CONTROL BOX
610
J3-4
J3-1
J3-3
LIGHT CODE
RHEOSTAT
STARTER
RELAY
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
CURRENT SENSING PC BOARD
CCW
64+/-6.4 OHMS MAX
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
DOWN DUE TO A FAULT (EVEN IF THAT CONDITION
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF FUEL), THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
62
FDW-5M EXCITER COIL:
SHUNT COIL WINDINGS ARE 65+/-1.5 OHMS EACH
SERIES COIL WINDINGS ARE .143 +/-.005 OHMS EACH
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
Return to Section TOC
BATTERY
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
STARTER
MOTOR
50A
G
25+/-1.25 OHMS EACH
W
BACK, BOTTOM
+ OF MACHINE
STARTER
SOLENOID
50
+
SERIES FIELD
LOCATED BEHIND UPPER LEFT
PORTION OF CONTROL PANEL
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
12 VOLT SUPPLY
REMOTE CONTROL PLUG
G
Y
610C
841
GLOW PLUGS
TYPICAL CURRENT
DRAW IS 40 AMPS
-40 TO 40 AMPS
AMMETER
841B
TEMPERATURE
GAUGE
LOWER LEFT OF
TEMPERATURE SWITCH / SENDER
SWITCH CLOSES
SENDER OPERATION: 212B CONTROL PANEL
AT 230v+/-6vF
140vF -> 134+/-13.5 OHMS
194vF -> 51.2+/-4.3 OHMS
SENDER IS APPROX.
212vF -> 38.5+/-3 OHMS
500 OHMS AT 70vF
FRONT, LEFT SIDE OFENGINE
S
I OIL PRESSURE
200
54
GAUGE
WK
G
G
LOWER LEFT OF
CONTROL PANEL
OIL PRESSURE SWITCH / SENDER
SENDER OPERATION:
SWITCH CLOSES
0 PSI -> 10+/-5 OHMS
AT 6+/-2 PSI
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
52B
55
G
53
51C
X
51
51A
SHOWN IN "OFF"
POSITION
44
W
18
61
212D
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
GLOW PLUG
BUTTON
IG
B
IGNITION
SWITCH
BACK, LEFT SIDE OF ENGINE
28
56
+
15
9
17
25
34
1
10
18
26
51B
K924-5 REMOTE CONTROL
(OPTIONAL)
DM
J. STAPP
UF
PIPELINER 200D (KUBOTA V2203M)
MACHINE SCHEMATIC
APPROVAL
08/04/2004
DATE:
PROJECT
NUMBER:
CRM35581
1
1 OF ___
PAGE ___
DOCUMENT
REVISION:
DOCUMENT
NUMBER:
L12362
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PIPELINER® 200
Return to Master TOC
Return to Master TOC
Return to Section TOC
G-9
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - CODE 11471 - (L13350)
CHANGE DETAIL: New
ENGINEERING CONTROLLED
MANUFACTURER: No
L13350
Return to Section TOC
G-9
JUMPER PLUG IS BEHIND LOWER
RIGHT SIDE OF CONTROL PANEL
11
87
1
ENGINE CONTROL UNIT (ECU)
2
86
2
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
RATED VOLTAGE: 12V
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
3
88
3
12 VOLT SUPPLY
94
ENGINE
SPEED
SENSOR
BACK, RIGHT
SIDE OF ENGINE
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
SENSOR OPERATION:
-4vF -> 18.80 kOHMS
104vF -> 1.14 kOHMS
212vF -> .16 kOHMS
93
20
17
60A
69
WATER
TEMP.
SENSOR
BACK, LEFT
SIDE OF ENGINE
CCW
26
64
SENSES ALTERNATOR OUTPUT
FLASHES ALTERNATOR
16
60
RATED VOLTAGE: 12V
RATED CURRENT: 2A
BACK, RIGHT
COIL RESISTENCE:
57
2.8 +/- .28 OHMS AT 20vC SIDE OF ENGINE
ENERGIZED FOR RUN
12 VOLT
ACTUATOR
DE-ENERGIZED FOR STOP
SUPPLY
ACTUATOR CONTROLS RPM
MECHANICAL STOP WILL SHUT
56
DOWN THE ENGINE AT 115%
OF RATED SPEED.
ENGINE
COLOR: RED
PROTECTION
61
12 VOLT
LIGHT
NORMALLY OFF
CENTER OF
841A
CONTROL PANEL
HOUR METER
CENTER OF
CONTROL PANEL
+
58
15
9
17
25
34
1
10
18
26
34
51B
212D
28
6
31
841B
844A
SWITCH CLOSES
AT 110v+/3vC
THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING
THE ENGINE PROTECTION LIGHT IN A CODED SEQUENCE,
SEE CHART FOR FAULT CODES AND CORRECTIVE MEASURES.
WHEN THE ENGINE IS SHUT DOWN DUE TO A FAULT,
27
THE IGNITION SWITCH WILL NEED TO BE TURNED OFF
THEN BACK ON TO RESTART THE ENGINE.
1
19
30
TEMPERATURE
SENSOR
SENDER OPERATION:
90vC -> 51.2+/-4.3 OHMS
TEMPERATURE SWITCH
7
32
12
CONNECT TO
CONNECT TO
GROUND FOR 70A
70B GROUND FOR
60F 60E
800RPM
1600RPM, LEAVE
OPEN LEAD IS WIRE-TIED INSIDE THE 70C UNCONNECTED
FOR 1800RPM
HARNESS BEHIND CONTROL PANEL
DC EXCITER USES RESIDUAL
MAGNETISM TO FLASH
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
-
+
STARTER
SOLENOID
50
50A
I
START
BUTTON
G
OIL PRESSURE SWITCH / SENDER
SENDER OPERATION:
SWITCH CLOSES
AT 6+/-2 PSI
0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
Return to Master TOC
Return to Section TOC
844
12 11 10 9 8 7 6 5 4 3 2 1
J5
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
842
DC AUXILIARY
RECEPTACLE
GND-T
730A
CURRENT SENSING PC BOARD
SCHEMATIC S25973
602A
4 6
720C
610D
3
1
2
P9
LOWER LEFT OF CONTROL PANEL
DRIVER
CIRCUITS
G
602
720A
720B
X
FUSE
15 AMP
W
REMOTE
RECEPTACLE
J3-2
730B
SHOWN IN LOCAL
POSITION
POSSIBLE CAUSE - CORRECTIVE MEASURE
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND
90-MIN
130-80
190-120
240-160
220-MAX
FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
LONG 1, SHORT 3
LONG 1, SHORT 4
"L" TERMINAL IS GROUNDED ON ALTERNATOR
FOR 1 SECOND
HIGH WATER TEMPERATURE DETECTED FOR 1
SECOND
SERIES FIELD
SELECTOR SWITCH
ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED
BROKEN OR LOOSE BELT - INSPECT
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
-
+
N
U
N
U
+
-
FJW-5AR COIL PAIR:
22.5+/-.5 OHMS EACH
SHUNT
BRUSH POSITION
FIELD
SHOWN AS VIEWED
FROM CONTROL PANEL
WELDING
GENERATOR
INTERPOLE
COILS
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
JUMPER PLUG IS
WIRE-TIED UP BEHIND
LOCAL / REMOTE
Y SWITCH ON RIGHT
SIDE OF MACHINE
LOCAL / REMOTE
SWITCH
GENERATOR LEAD BLOCK
SHOWN AS VIEWED WITH
ENGINE IN THIS DIRECTION
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
602B
41
42
JUMPER PLUG IS
WIRE-TIED UP BEHIND
LOCAL / REMOTE
SWITCH ON RIGHT
SIDE OF MACHINE (AS
VIEWED FROM
CONTROL PANEL)
J8
5
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN SAME (CURRENT
FLOW) DIRECTION AS SHOWN
RHEOSTAT
64+/-6.4 OHMS MAX
CCW
67B
LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM)
FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
P10
THE P10 PLUG IS ONLY ON UNITS WITHOUT
THE WIRE FEED MODULE. THE WIRE FEED
MODULE HAS A HARNESS THAT PLUGS
DIRECTLY INTO J5.
FDW-5M EXCITER COIL:
SHUNT COIL WINDINGS ARE 65+/-1.5 OHMS EACH
SERIES COIL WINDINGS ARE .143 +/-.005 OHMS EACH
3 TURNS
FAILURE DETECTED
REMOTE CONTROL BOX
WIRE-TIED TO HARNESS
BEHIND CONTROL PANEL
610B
J3-4
J3-1
J3-3
LIGHT CODE
RHEOSTAT
STARTER
RELAY
+
SERIES FIELD
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
RESISTOR: OHMS/WATTS
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT 1
0 RPM IS DETECTED AND 12V IS DETECTED
FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
FROM "L" TERMINAL ON ALTERNATOR
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
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LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
LONG 2, SHORT 6
0 VOLTS DETECTED FROM "L" TERMINAL ON
ALTERNATOR FOR 1 SECOND
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
LONG 2, SHORT 8
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
INCORRECT BATTERY - INSPECT
FAULTY ALTERNATOR - CHECK
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
ACTUATOR SENSED BY ECU
CONNECTOR PIN NUMBERS:
67A
_
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
N-BROWN
+
NEGATIVE OUTPUT TERMINAL
POSITIVE OUTPUT TERMINAL
TYPICAL OCV (WARM MACHINE):
88-98 VOLTS AT MAX RHEOSTAT
47-60 VOLTS AT MIN RHEOSTAT
UNDER LEFT DOOR
BROKEN OR LOOSE BELT - INSPECT
FAULTY ALTERNATOR - CHECK
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
25+/-1.25 OHMS EACH
CCW
610
LOCATED BEHIND UPPER LEFT
PORTION OF CONTROL PANEL
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
12 VOLT SUPPLY
W
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
DOWN DUE TO A FAULT (EVEN IF THAT CONDITION
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF FUEL), THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
52A
610C
841
BATTERY
64+/-6.4 OHMS MAX
212C
OIL PRESSURE
GAUGE
LOWER LEFT OF
CONTROL PANEL
X
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
STARTER
MOTOR
62
S
+
Y
BACK, BOTTOM
OF MACHINE
55
SHUNT FIELD
-
FRONT, LEFT SIDE OF ENGINE
200
WK
G
REMOTE CONTROL PLUG
G
52B
DC EXCITER
GND-B
54
GLOW PLUGS
TYPICAL CURRENT
DRAW IS 40 AMPS
-40 TO 40 AMPS
AMMETER
51
51A
841B
TEMPERATURE
GAUGE
LOWER LEFT OF
212B CONTROL PANEL
G
ECU CONNECTOR DETAIL
9
212E
SHOWN IN "OFF"
POSITION
BACK, LEFT SIDE
212A
OF ENGINE
S
I
43
44
18
53
IG
B
IGNITION
SWITCH
FRONT , RIGHT SIDE
OF ENGINE
K924-5 REMOTE CONTROL
(OPTIONAL)
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
GLOW PLUG
BUTTON
10,000 +/- 1,000 OHMS MAX
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
BACK, LEFT SIDE OF ENGINE 51C
ALTERNATOR
40 AMP / 12 VOLT
L
4
13
LOWER RIGHT OF CONTROL PANEL
RPM CONTROL POTENTIOMETER
PROPRIETARY &
EX. 12 PIN CONNECTOR
LABELS:
COMMON
1 2
FRAME GROUND
7
6
12
EARTH GROUND
LATCH
VIEW OF CONNECTOR ON PC BOARD
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
CONFIDENTIAL: THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
Maglietta
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
ENGINEER: D. BENDER
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
APPROVED:
-
DO NOT SCALE THIS DRAWING
SCALE:
NONE
IF PRINTED
@ A2 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
NA
PIPELINER 200D KUBOTA
MACHINE SCHEMATIC
APPROVAL
11/16/2007
DATE:
PROJECT
NUMBER:
REFERENCE:
CRM37569
L12362
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
L13350
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PIPELINER® 200
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Return to Section TOC
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G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - CURRENT SENSE PC BOARD - CODE 10929,11114, 11316, 11471 - (S25973)
ENGINEERING CONTROLLED
MANUFACTURER: No
S25973
Return to Section TOC
G-10
CHANGE DETAIL: NEW
DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:THIS
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
REFERENCE:
EQUIPMENT TYPE:
ON 2 PLACE DECIMALS IS ± .02
SCALE:
SUBJECT:
ON 3 PLACE DECIMALS IS ± .002
DRAWN BY:
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE
WITH PUBLISHED STANDARDS.
ENGINEER:
DO NOT SCALE THIS DRAWING
APPROVED:
BTV
DM
NONE
MATERIAL
DISPOSITION:
CLASSIC SERIES
CURRENT SENSE PC BOARD SCHEMATIC
NA
APPROVAL
DATE:
4/1/2004
PROJECT
NUMBER:
CRM34866
1
1 OF ___
PAGE ___
DOCUMENT
NUMBER:
S25973
DOCUMENT
REVISION:
A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PIPELINER® 200
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ELECTRICAL DIAGRAMS
G-11
SCHEMATIC - IDLER/ENGINE SHUTDOWN - CODE 10929 (L10826)
Return to Master TOC
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G-11
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PIPELINER® 200