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Lincoln Electric 200 Welder User Manual

1. 1 9 gt g Safety Precautions amp Design Summary BB 2 o Engine Operation amp Cold Weather 0 1 BB 3 Welder Operation amp Engine Break In BB 4 Idler Operation amp Auxiliary Power BB 5 Return to Master TOC o He 9 5 Return to Master PIPELINER 2000 PERKINS LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC ojo o E 5 5 8 R7 9 1 0 gt 813 Return to Section TOC Return to Master TOC Return to Master TOC BB 2 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e 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 40 MOVING PARTS can injure
2. 3 TURNS eio E ojeg 3 O0 512 2 c PLUG FOR REMOTE CONTROL ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 POTENTIOMETER CONNECT P5 ON W F M TO CONNECTOR J5 ON MACHINE INLINE CONNECTORS PLUG P5 B W PANEL WIRE FEED CONNECT TO POS amp NEG fo POS MODULE RECAEN 9 NEG 42 HEAVY LEAD RESISTORS OUTPUT TERMINAL E 42 HEAVY LEAD CONNECT TO CASE CONNECT TO NEG 250 AMP THERMOSTAT ASSEMBLY MACHINE MUST BE RUNNING WHEN MAKING THESE CONNECTIONS REMOTE CONTOL POTENTIOMETER BOX M20464 Return to Section TOC Return to Master TOC 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 LINCOLN amp PIPELINER 200 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio E ojeg 3 O0 512 2 c Return to Section TOC Return to Master TOC G 6 WIRING DIAGRAM CODE 11471 M21564 LINCOLN 8 ENGINE CONTROL UNIT CONNECTOR DETAIL GLOW PLUGS WIRE TIED TO WIRING HARNESS BEHIND CONTROL P
3. POSITIVE OUTPUT TERMINAL Return to Master TOC PIPELINER 200 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo Fie 5 5 R7 9 1 0 gt 813 oO oO Return to Section Return to Master TOC E THEORY OF OPERATION E FIGURE E 2 GENERAL DESCRIPTION ENGINE FROM CURRENT HOUR SENSING P C BOARD TO MEER ENGINE CONTROL PROTECTION lt MODULE SELECTOR m CURRENT E SEXSNGPE BOARD E DUER SENENG PE OAD IDLER ENGINE NEGATIVE 1 n Pr PROTECTION OUTPUT P C BOARD lus ped Y TERMINAL Board gt CONTROL THROTTLE UNIT Booy seme colmo EN CONTROLLER rac led ma ae PH Yn Yon ENGINE m RESIDUAL 2 79
4. 2 5 Return to Section Return to Master TOC o p 8 5 2 OPTIONAL EQUIPMENT eto isrALLED K704 Accessory Set Includes 35 ft 10 7m electrode and 30 ft 9 1m work cables headshield work clamp and electrode holder A 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 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 2464 1 Contains remote control rheostat for adjusting the CC STICK remote control potentiometer for adjusting the CV WIRE OCV and 100 ft 30 5m cable Easy Installation ACCESSORIES CCC 2 K953 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable federal state and local laws regard ing possible additional requirements There is a choice of 2 hitches a fender amp a light package
5. G 7 Schematic Complete Machine Code 11114 11316 112362 G 8 Schematic Complete Machine Code 11471 L13350 G 9 Schematic Current Sense PC Board Code 10929 11114 11316 11471 525973 G 10 Schematic Idler Engine Shutdown Code 10929 10826 G 11 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi lay ered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided PIPELINER 200 LINCOLN 8 2 WIRING DIAGRAM CODE 10660 111402 ELECTRICAL DIAGRAMS G 2 PIPELINER 2006 WIRING DIAGRAM ELECTRICAL SYMBOLS PER E1537 ZENITH THROTTLE RPM CONTROL 5 LEAD COLOR CODE 1 B BLACK 15 CONNECTOR GREEN BLACK N BROWN CONNECTOR R RED 1 2 3 4 5 8 911 12 13 17 U BLUE Y W WHITE Y YELLOW CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU B TI Return to Section TOC Return to Master TOC THROTTLE PLATE ace ALTERNATOR PARTS SUPPLIED WITH ENGINE ENGINE HOUR METER 6 gt J8 P9 SELECTOR RECEPTACLE B SWITCH SENDER SENSOR TTT Return to Section TOC Return to Master TOC IDLER SWITCH
6. PIPELINER 2000 PERKINS LINCOLN 8 DD 5 5 Bind PIPELINER 2000 PERKINS LINCOLN DD 6 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes BARS TABLE OF CONTENTS INSTALLATION SECTION BRE lnstallatioh iw Ra era da d AAA 1 Technical Specifications 4 AAA 2 Return to Master TOC Safety Precautions rris AAA 3 Angle of Operation bre esr eate E E eee 4 Pre Opetation Service ca den 5 Return to Master o He 9 5 Return to Master PIPELINER 200G LINCOLN B Return to Section Return to Master TOC Return to Section TOC olo o Fle equ 9 10 gt 812 cfc 515 pir oO oO Return to Section Return to Master TOC Return to Master TOC add INSTALLATION TECHNICAL SPECIFICATIONS Pipeliner amp 200G K6090 7 INPUT GASOLINE ENGINE Make Model Description Speed RPM High Idle 1600 4 Oylinder GM 4 Cycle 3 0 Liter Full
7. SCALE SUBJECT NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual CAPACITOR MFD VOLTS RESISTOR OHMS WATTS CONNECTOR PIN NUMBERS EX 12 PIN CONNECTOR 12 6 7 12 LATCH VIEW OF CONNECTOR ON PC BOARD THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY BE DUPLICATED COMMUNICATED OTHER PARTIES USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERM PIPELINER 200D KUBOTA V2203M MACHINE SCHEMATIC MATERIAL APPROVAL PROJECT 08 04 2004 5581 ION OF LINCOLN GLOBAL INC PAGE 1 1 DOCUMENT DOCUMENT NUMBER REVISION L12362 A G 8 PIPELINER 200 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio E ojeg 3 O0 9 dc 5153 5 clo Return to Section TOC Return to Master TOC G 9 SCHEMATIC COMPLETE MACHINE CODE 11471 L13350 LINCOLN 8 086611 RATED VOLTAGE 12V RATED CURRENT 22mA MAX SPEED BACK RIGHT SIDE OF ENGINE SENSOR OPERATION AV gt 18 80 5 104 gt 1 14 5 212 gt 16 RATED VOLTAGE 12V RATED CURRENT 2A COIL RESISTENCE 2 8 28 OHMS 200 SIDE OF ENGINE ENERGIZED FOR RUN DE ENERGIZED FOR STOP ACTUATOR CONTR
8. 0 gt 4 1 LAMP Leni ier os 2 onesk tS Ju m eme iioii 1 dE oe mej 21 ELI iain 5 n T inae 1 0 5 5 pue 114 Bl Sip TEES E fale 2 S zx 9 45388 ee 109 ii 33 d HT 188 L gt m Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN PIPELINER 200
9. 1811 Engine oil filter 215 tae Drain water separator amp fuel strainer E Tension of alternator drive belt 2 1 Alternator drive belt wear R Alternator drive 17480 97010 5 9 Jecl 1 Air filter earlier check may be req d R Air filter element Donaldson st P821575 1 1 Vaw clearances Intake 0071 0086 Exhaust 0071 0086 12 1 20 Inspect Clean 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 525833 Fle 5 5 0 gt 815 43 Return to Section Return to Master TOC PIPELINER 2000 KUBOTA LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo o Fie 5 5 8 R7 9 1 0 gt 813 oO oO Return to Section Return to Master TOC DS MAINTENANCE Oc Case Front Ass
10. CONTROL PA NEL OE SES GROU ND SCR EW THESE LEADS MUST BE ROUTED THRU CURRENT SENSOR THE CURRENT FLOW DIRECTION AS SHOWN GROUND POSITIVE TO ENGINE CC amp CV WITH W F M 924 4 REMOTE CONTROL OPTIONAL REMOTE CONTROL RECEPTACLE amp SWITCH ON MACHINE REMOVE PLUG P10 FROM CONNECTOR 5 CONNECT PLUG P5 ON W F M TO CONNECTOR J5 ON MACHINE 1 eio E ojeg 3 O0 9 512 clo Return to Section TOC Return to Master TOC LINCOLN 8 113144 SEE o B 12111098765 43 BELOW R P11 SEE BELOW ina CAUTION DAMAGE CAN OCCUR 24184 TO THE REMOTE CONTROL SWITCH IF IT IS USED 3 42 WITHOUT THE P11 PLUG 4 602 INSTALLED OR A WIRE 5 FEED MODULE INSTALLED 6 gt RESISTORS P8 REMOTE CONTROL SWITCH FOR LOCAL OR REMOTE CONTROL POTENTIOMETER BOX SHOWN IN LOCAL POSITION WITH MACHINE NOT RUNNING REMOVE PLUG P9 ON MACHINE FROM CONNECTOR J8 THEN CONNECT PLUG P8 ON REMOTE CONTROL TO CONNECTOR J8 ON MACHINE IF A WIRE FEED MODULE IS INSTALLED WITH THE MACHINE OFF DISPOSE OF THE UNCONNECTED 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 CONNECT
11. 5 2 5 Return to Section Return to Master TOC o 2 0 8 5 INSTALLATION ida TECHNICAL SPECIFICATIONS Pipeliner amp 200D K6090 9 INPUT DIESEL ENGINE Make Model Description Horsepower Operating Displacement cu in Itrs Starting Capacities SPEED System 12VDC Battery and starter Fuel 15gal 57L 4 Stroke High OB T qs Naturally 1600RPM 8 7 qts Perkins Aspirated 1600RPM Push Button 8 2L 104 22 Water Full Load 135 6 2 2 Starter Cooled 1550RPM Engine Low Idle 650 Cold Radiator Coolant 1400RPM crank amps 9 5 qts 9 0L RATED OUTPUT 104 F 40C WELDER DESCRIPTION RATED DC OUTPUT DUTY CYCLE DC CURRENT RANGE VOLTS RATED AMPS Fine Adjustment in each Range 200 Amp DC Welder Lincoln Plus Rating 40V 200A All Copper Windings 40 300 Amps Pure DC Power NEMA Rating 28V 200A Generator RATED OUTPUT 104 F 40C GENERATOR 1 80 kW 15 Amps 120V DC 35 Duty Cycle ENGINE COMPONENTS Full Pressure with Full Flow Filter Indirect Fuel Injector Mechanical Governor Electrical Shutoff Solenoid Mechanical Fuel Pump Low noise Muffler Shutdown on low oil Single Element Automatic Idler Made from long life pressure and engine aluminized steel temperature PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 40 94 in 24 00 in 66 50 1039 9 609 6
12. Return to Master TOC PIPELINER 200 LINCOLN Return to Section Return to Master TOC Return to Section TOC ojo o Fie 5 8 R7 9 1 0 gt 813 oO oO Return to Section TOC Return to Master TOC Return to Master TOC F 28 TROUBLESHOOTING amp REPAIR ENGINE ALTERNATOR TEST CONTINUED FIGURE F 9 ALTERNATOR LEAD LOCATIONS BACK OF ALTERNATOR TEST PROCEDURE Turn the engine off Open the engine access door and check the voltage at the battery terminals It should be approximately 12 volts DC Attach the meter leads to the battery terminals being careful to position them so they stay clear of moving parts while the engine is run ning Place the idle switch in the HIGH IDLE posi tion start the engine and allow it to run at high idle speed for about 15 to 30 seconds The meter should read about 13 7 to 14 2 VDC If the meter reads correctly the engine alterna tor is producing adequate power to charge the battery and this test is complete If the voltage is significantly higher than the above values the alternator is not properly regulating the battery charging voltage and should be replaced the voltage reads the same or less than the measurement taken when the engine was not running proceed with the following tests Turn off the engine disconnect the meter from the battery and open the engine access door on the left side of the machine
13. Return to Section TOC Return to Master TOC LOOSEN HERE Return to Section TOC Return to Master TOC 12 Using the slot head screw driver remove the choke control cable from the engine carbure tor assembly Mark cable replacement for reassembly See Figure F 21 O10 5 10 9 1 0 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN 8 ojo o E 5 5 8 R7 9 1 0 gt 813 Return to Section TOC Return to Master TOC 13 14 15 16 17 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 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 Disconnect the blue and brown main shunt leads from their quick disconnect splices See the Wiring Diagram Disconnect the leads from the START button switch See Figure F 22 and the Wiring Diagram Remove the leads from the ignition switch Label for reassembly See Figure F 22 and the Wiring Diagram 18 19 20 Using the 3 8 nut driver remove the leads from the ammeter Label for reassembly See Figure F 22 and the Wiring Diagram Label and remove
14. not operate with doors open or guards off c Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s 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 amp 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 amp 200D will provide constant volt age output for running the LN 25 wire feeder The optional Remote Control Kit provides a remote control rheostat for remote fine current and open circuit voltage adjustment The Pipeliner amp 200D has Diesel Engine Protection In the event of sudden low oil pressure or high coolant temperature the engine immediately shuts down OPERATION BB 2 The Pipeliner amp 200D has a current range of 40 300 DC amps with output ratings as follows RATED OUTPUT DUTY CYCLE 200A 28V 200A 40V 60 60 The unit is also capable of providing 1 80 kw of 120V DC auxiliary power at 3596 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
15. HERE D T 1 RT 1 mm 108 222 ag a E ToT 2 n jur 5 o C m amp FEE s o 158 47 i c2 ude 8 Gja or nes Ser i 9 Eus op mM BI dic d 1 ad egg T 22 xb a 0 L Es T 9 8 pe te gt Ana i 5 2 e c gt BR er wae 23 ss S Hinh 15 DIRETTA GHU HUN Vink HJA H BOARD CHANCE D CIR MERHAR FABRIL OF COMPLETE BAART THIS MAY SGT 5H THE COMPONENTS DA CIRCUITRY CONTROLS A COJI MTZ QR CCRCUITSY XM A PRINT 1 15 407 TD FE SUDUTED MES LEISED OF 5520 THp EXPRESS ELELTRIC FEE meom PAGARIRTARY Er THE LINCOLN ELECTRIC 1 E 812 1 1 s 2 US 3 WD E olo ak 8 2 ENGINE 5 az AE FIO 4 308 280 cp FE C 1 z
16. a Return to Section TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS WARNING 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 neces sary 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 e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 3 4 MOVING PARTS can injure not operate with doors open or guards off Ys Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s 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 Se
17. 10 9 1 0 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN 8 pu TROUBLESHOOTING amp REPAIR dd MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 24 BRUSH BRACKET WRAP AROUND COVER Return to Section TOC Return to Master TOC BRUSH BRACKET REMOVE 2 NUTS WASHERS AND SCREWS WRAP AROUND COVER Return to Section TOC Return to Master TOC 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 FIGURE F 25 MAIN GENERATOR BRUSH BRACKET CLAMPING BOLT ojo o Fie 5 5 8 R7 9 1 0 gt 813 oO oO 28 Lift the eight brushes from the main commu 29 Using the 7 16 wrench loosen do not tator Note their positions for reassembly remove the main generator brush bracket clamping bolt Note the position of the drill spot for reassembly See Figure F 25 Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B ree TROUBLESHOOTING amp REPAIR pon MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 26 MAIN GENERATOR FEET MOUNTING Return to Section TOC Return to Master TOC MAIN GENERATOR FEET 2 REMOVE MOUNTING NUTS WASHERS AND BOLTS Return to Section TOC Return to Master TOC 30 Using the 3 4 wrench remove the frame mounting bolts nuts
18. 4 TRAILERS 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 dam age 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 rough ness of surface on which the trailer will be operat ed 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 pub lic highways VEHICLE MOUNTING A WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail e 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 compo nents such as suspension axles and tires Mount equipment base to me
19. eum qur SUBJECT CURRENT SENSE PC BOARD SCHEMATIC NONE ne NE 525973 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PIPELINER 200 ELECTRICAL DIAGRAMS SCHEMATIC IDLER ENGINE SHUTDOWN CODE 10929 110826 gt 8 5 ble E 8 9 5 Bg 2 8848 2 EDER Jel z gt 58 a mE lt 5 18 515 nr uu 2582 55 1 Boi PATT ojo pi dis En LE 0 46 Ua T dig zu m wr Ld MU 45388 15366 ij z i 1 BE 3 2 est Ed E Y i ED MET gt RUM SWITLH 29 i a 8 25 4 76 ul a ji gin m 5 3 5 merge 028 8 gt ED X 5 O MR 1 ZET vaa i F 2 O m x Wo manaa d of RESET IH Af t oe SY y 158 Deme aa th 163 3 d _ 3 do aqu fee mov 1
20. 28 28 OHMS 20 C ENERGIZED FOR RUN DE ENERGIZED FOR OF RATED SPEED COLOR RED 12 VOLT NORMALLY OFF ENGINE SENSOR BACK RIGHT SIDE OFENGINE ENGINEERING CONTROLLED CHANGE DETAIL Released 02 from X MANUFACTURER No 12 VOLT SUPPLY LOCATED BEHIND UPPER OF CONTROL PANEL RATED VOLTAGE 12V RATED CURRENT 4 5A MAX TERMINAL 15 LEAKAGE CURRENT 10 A MAX TERMINAL 16 1 04 20 9 17 WATER TEMP SENSOR BACK LEFT SIDE OFENGINE 57 BACK RIGHT ENGINE PROTECTION _ C 61 9 LIGHT CENTEROF g4 CONTROL PANEL HOUR METER CENTER CONTROL PANEL 12 VOLT STOP ACTUATOR SUPPLY ACTUATOR CONTROLS RPM MECHANICAL STOP WILL SHUT DOWN THE ENGINE AT 115 60 77 CONNECTOR DETAIL THE 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 30 32 CONNECT TO CONNECT TO GROUNDFOR 70A 70B GROUND FOR 800RPM 1600RPM LEAVE OPEN LEAD IS WIRE TIED INSIDE THE UNCON
21. 5 2 5 Return to Section Return to Master TOC 2 8 5 5 OE This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W 30 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 Fill the fuel tank with the grade of fuel recommended in the Engine Operator s Manual Make sure fuel valve on the sediment bowl and water separator are in the open position FUEL 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 alter nate antifreeze recommendations INSTALLATION AA 5 BATTERY CHARGING WARNING GASES FROM BATTERY can explode e Keep sparks 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 nega tive cable from the old battery first and con nect the negative
22. 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 remote control potentiometer for adjusting CV STICK OCV and 100ft 30 5m cable See Wiring Connection Diagram Section 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 pos sible additional requirements Choice of 2 hitches and add on fender 8 light package Order 953 1 Trailer K958 1 Ball Hitch 958 2 Lunette Eye Hitch K959 1 Fender amp 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 ACCESSORIES 2 Wire Feed Module 623 1 Provides constant volt age 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
23. Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section TOC Return to Master TOC o 2 0 8 5 ACCESSORIES OPTIONAL FEATURES Field Installed GENERAL OPTIONS 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 feder 8l state and local laws regarding possible additional require ments There is a choice of 2 hitches a fender amp a light pack age K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit K965 1 Cable Rack 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 head shield work clamp and electrode holder Cable is rated at 500 amps 6096 duty cycle Remote Control Kit K924 5 Contains remote control rheostat and 100 ft 30 5 m c
24. o m 5 2 5 Return to Master TOC 11 Replace plug P10 making sure the leads and plug are secure o 8 515 5 Locate the U pin 3 and the brown 9 If the plug and associated leads are okay 5 5 leads in the harness plug the shunt field coils may be faulty Replace o s Figure F 6 the shunt field coils 2 2 812 6 Using volt ohmmeter measure the resis 10 If the test does meet the resistance specifi tance between the blue and the brown lead cations the main shunt coils are okay it E Normal resistance is approximately 40 a ohms 7 Also measure the resistance from either lead blue or brown to ground This resis tance should be at least 500 000 ohms 12 After the test and repairs are completed close and latch the right side door 8 If the test does not meet the resistance specifications then check the harness plug for loose connections or shorted leads Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B 22 5 PIPELINER 200 LINCOLN amp F 22 901 01 901 J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL uonoes DOL uonoes DOL TROUBLESHOOTING 8 REPAIR dini FLASHING THE FIELDS WARNING Service
25. 10 9 1 0 lz 813 pir oO oO r t 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 AUXILIARY POWER 1 80 kW of 120V DC auxiliary power at 3596 duty cycle maximum is available at the receptacle located on the control panel Return to Section TOC Return to Master TOC PIPELINER 2000 PERKINS LINCOLN B 5 PIPELINER 2000 PERKINS LINCOLN BB 6 901 J91Se N DOL J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes 1 TABLE OF CONTENTS ACCESSORIES SECTION 1 AGCesSOFleS 8 CC 1 Optional Features PERPE CC 2 Return to Master TOC Return to Master TOC o He 9 5 Return to Master PIPELINER 2000 PERKINS LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 2 5 2 5 Return to Section Return to Master TOC Q p 8 5 2 OPTIONAL FEATURES Field Installed Accessory Set K704
26. Installation Perkins 104 22 K6090 9 Section AA Operation Kubota V2203M 6090 11 Section B Accessories Kubota V2203M 6090 11 Section C Accessories Perkins 104 22 K6090 9 Section CC Maintenance Kubota V2203M K6090 11 Section D Maintenance Perkins 104 22 6090 9 Section DD Parts Manual Perkins 104 22 K6090 9 P 448 Parts Manual Kubota V2203M K6090 11 P504 PIPELINER 200 LINCOLN B Bnet TABLE OF CONTENTS INSTALLATION SECTION Bet o o 5 installati n deat 1 9 g 6 2 5 Ra Ru epe ee VER 2 General Description amp Design Features A 3 Pre Operation Installation amp Grounding 4 4 Trailer Polarity Controls Fuel amp Cooling System 1 A 5 Battery Charging ee
27. Return to Master TOC F 17 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST A 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 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 trou bleshooting 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 LINCOLN F 17 TROUBLESHOOTING 8 REPAIR Fm IDLER SOLENOID TEST continued FIGURE F 4 IDLER SOLENOID CONNECTIONS Return to Section TOC Return to Master TOC QUICK CONNECT LEADS o m 5 2 5 Return to Master elo e e ele TEST PROCEDURE olo 5 9 1 Turn the engine OFF 7 the solenoid does not operate properly check for 9 a mechanical restriction in the linkage or for
28. sible misaligned shaft Have an authorized Field Service Shop check and realign the shaft MAINTENANCE DD 3 IDLER MAINTENANCE CAUTION Before doing electrical work 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 con nected properly The correct polarity is negative ground Damage to the engine alternator and the print ed 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 ground ing 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 automat ic 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 SYSTEM Perkins 104 22 Engine 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 s
29. 1 In the High position the idler is off and the engine runs at the high speed controlled by the gov ernor This speed can be adjusted between 1500 and 1600 RPM using the RPM dial on the output rail 2 In the Automatic lt gt position the idler operates as follows 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 f 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 LINCOLN B epos TABLE OF CONTENTS ACCESSORIES SECTION eue 80 2 2 2 ol stele dte oh a tessa e ld a oa dria Pene CCC 1 Optional Equipment amp Remote 5 CCC 2 Return to Master TOC Return to Master TOC o He 9 5 Return to Master PIPELINER 200G LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5
30. 1689 1 1318 Ibs 598 kg Top of enclosure add 8 0 203 2mm for exhaust 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 2000 PERKINS LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC olo o Fle 9 1 812 cfc 515 oO oO Return to Section TOC Return to Master TOC Return to Master TOC AA 3 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves 3 ENGINE EXHAUST can kill 4 Use in open well ventilated areas vent exhaust outside MOVING PARTS can injure not operate with doors open or guards off A Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual EXHAUST SPARK ARRESTER Some federal state or loc
31. Alternator Output Leads 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 Place the negative meter probe on a good chassis ground or the negative battery termi nal Place the positive meter probe on the bat tery terminal on the back of the alternator Lead 51 See Wiring Diagram The meter should read about 13 7 to 14 2 VDC Move the positive probe to the DT terminal on the back of the alternator Diagram See Wiring The meter should read about 13 7 to 14 2 VDC If the meter reads correctly check the connec tions between the alternator and the battery See wiring diagram 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 LINCOLN B F 28 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC 2 8 5 29 TROUBLESHOOTING amp REPAIR F 29 OIL PRESSURE TEMPERATURE SWITCH TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equip
32. Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place Mar 93 PIPELINER 200 LINCOLN MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Installation Kubota 2203 6090 11 Section A
33. 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 unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an outside area INSTALLATION 4 CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES 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 gen eral if the machine is to be grounded it should be con nected 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 te
34. 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 amp 200D is equipped with a pressure radi ator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodical ly to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type ENGINE MAINTENANCE Refer to the Engine s operation and mainte nance manual for additional information on the engine PIPELINER 2000 PERKINS LINCOLN B Return to Section Return to Master TOC Return to Section TOC ojo o E 5 5 8 R7 9 1 0 gt 813 Return to Section Return to Master TOC Return to Master TOC 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 con stantly or in excessively dirty locations it may be nec essary 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 Over greasing 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 introduce
35. amp 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 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 trou bleshooting 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 LINCOLN eae TROUBLESHOOTING amp REPAIR Ee DC EXCITER ARMATURE amp FIELD COILS REMOVAL AND REPLACEMENT PROCEDURE FIGURE F 15 EXCITER COVER REMOVAL Return to Section TOC Return to Master TOC POLE PIECE BOLTS 4 EXITER FRAME N BRUSH HOLDER ARMATURE ASSEMBLY 2 SLEEVE COLLAR FLAT WASHER ARMATURE LOCKING NUT EXITER COVER m 5 2 5 Return to Master TOC PROCEDURE 9 9 Armature Removal Procedure Reassembly 5 1 the engine OFF 7 Upon r
36. and washers from the feet of the main generator See Figure F 26 FIGURE F 27 MAIN GENERATOR ENGINE MOUNTING SLING ENGINE GENERATOR MOUNTING HOLES ojo o Fie 5 5 8 R7 9 1 0 gt 813 oO oO 31 With the rope sling around the genera 32 Using the 9 16 wrench remove the bolts tor frame carefully lift the frame a small dis and lock washers mounting the generator tance Slide the wood or steel blocks under frame to the engine See Figure F 27 the engine See Figure F 27 Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC ojo O o Fie 5 5 810 9 0 gt 813 oO oO r t Return to Section TOC Return to Master TOC Return to Master TOC F 59 TROUBLESHOOTING amp REPAIR 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 Reassembly Refer to Figures F 26 amp 27 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 Using the 9 16 wrench install the bolts and lock washers mounting the g
37. being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operat ed environmental conditions likely maintenance INSTALLATION 4 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specific requirements for use on pub lic highways VEHICLE MOUNTING A WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail e Only transport this Equipment on serviceable vehi cles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehi cle Follow vehicle manufacture s 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 mount ing 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 t
38. system may be necessary Use qualified personnel to do this per the instructions in thelMAINTENANCE sec tion of this manual PIPELINER 200D WITH PERKINS 104 22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA Low idle 1400 RPM 33gal hr 1 25ltrs hr No Load High idle 1800 Rpm No load 39gal hr 1 48ltrs hr 200 Amps 28 Volts 200 Amps 40 Volts Auxiliary Power 15 Amps 120 Volts 67gal hr 2 54ltrs hr 75gal hr 2 84ltrs hr 50gal hr 1 89ltrs hr PIPELINER 2000 PERKINS LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 10 9 1 0 gt 813 pir oO oO Return to Section TOC Return to Master TOC BB 4 ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial 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 suc cessful engine break in most diesel powered equip ment needs only to be run at a reasonably heavy load within the rating of the welder for some period of
39. 1125 p vane PERKINS DIESEL E ACTUATOR son b GENERATOR zem i LTERNATOR COUPLING ARMATURE EN Eus em mt 4 527 4 GASOLINE COUPLED TO DIESEL ENGINE 22222 GENERATOR 4 isave DSE GENERATOR WIERPOLE m ENGINE Cols Qh 8999 L 1 L Y FIELD CONTROL POSITIVE OUTPUT TERMINAL GENERAL DESCRIPTION The PIPELINER 200 is a heavy duty engine driven DC arc welding power source capable of providing con stant current output for stick welding or DC TIG weld ing 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 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o Fie 5 5 R7 9 1 0 gt 813 oO oO Return to Section TOC Return to Master TOC ES THEORY OF OPERATION FIGURE E 3 PROTEL BATTERY STARTER ENGINE ALTERNATOR OIL amp TEMPERATURE SWITCH CIRCUITS 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 appr
40. 8 5 FIGURE E 1 BLOCK LOGIC DIAGRAM FROM CURRENT SENSING BOARD ENGINE CONTROL PROTECTION MODULE ELEC e FROMCUF JRRENT SWIT p snsc Bono zem PIT IDLER D 5 E m Senor toO swm IDLER ENGINE NEGATIVE d 1 H Hi EH protection 11541 6 BOARD L Sensing gt 1 Board BATTERY ENGINE ZENITH THROTTLE E c ECU wu CONTROLLER 5 TANE t M m re RESIDUAL MAGNETISM E PERKINS DIESEL Sam ENGINE Ax ica GENERATOR ARMATURE cous gt p DIESEL GENERATOR ENGINE GENERATOR 3 LM MECHANIC ma M COUPLIN aowruxs B ed A ou KUBOTA COUPLED TO Em GASOLINE COUPLED TO Thid
41. 813 oO oO r t Return to Section TOC Return to Master TOC F 38 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST CONTINUED PERKINS ONLY FIGURE F 13 BLOWER PADDLE MARK LOCATION BLOWER PADDLE MARK PROCEDURE Strobe Tach Method 1 2 Turn the engine off Unlatch lift and secure the right side door Note Latches are located at both ends of the door 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 loca tion Connect the strobe tach according to the manufacturer s instructions Start the engine and direct the strobe tach light on the blower paddle rotating mark With the machine at HIGHIDLE the tach should read between 1540 and 1650 RPM With the machine at LOW IDLE the tach should read between 1375 and 1425 RPM Synchronize it to the PIPELINER 200 LINCOLN B F 38 pus TROUBLESHOOTING amp REPAIR pus ENGINE THROTTLE ADJUSTMENT TEST CONTINUED PERKINS ONLY PROCEDURE 6 If either of the readings is incorrect adjust the throt tle as follows Adjust HIGH IDLE The Engine is Preset at factory Contact Perkins 1 888 737 5364 or www perkins com Adjust LOW IDLE 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 Return to Section TOC Return to Master TOC Us
42. COOLANT INCORRECT CHECK FAULTY WATER TEMPERATURE SWITCH CHECK THAT STUD IS OPEN WHEN ENGINE IS NOT RUNNING 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 FROM L TERMINAL ON ALTERNATOR FAULTY RPM SENSOR CHECK FOR GOOD CONNECTION 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 LONG 2 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 SHORT4 50 WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR CHECK FOR PROPER RESISTANCE LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN CHECK FOR CONTINUITY LONG 2 SHORT 5 150C WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR CHECK FOR PROPER RESISTANCE LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED CHECK LONG 2 SHORT 6 0 VOLTS DETECTED FROM L TERMINAL ON ALTERNATOR FOR 1 SECOND LEAD TO L TERMINAL ON ALTERNATOR BE OPEN CHECK FOR CONTINUITY BROKEN OR LOOSE BELT INSPECT FAULTY ALTERNATOR CHECK LONG 2 SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR INCORRECT BATTERY INSPECT FAULTY ALTERNATOR CHECK LONG 2 SHORT 8 LESS THAN 4 VOLTS TO RPM SENSOR AND OR ACTUATOR
43. D 40 TO 40 AMPS AMMETER SHOWN IN OFF POSITION BACK LEFT SIDE 4 OF ENGINE 5 oo 43 841B m TEMPERATURE TEMPERATURE GAUGE TEMPERATURE SWITCH TEMPERAT LOWER LEFT OF SENDER OPERATION 2128 OONTRO PANEL FRONT RIGHT SIDE OF ENGINE 28 44 STARTER MOTOR 777 BACK BOTTOM 309 50 STARTER OF MACHINE 5 SOLENOID BATTERY 12 6 VOLTS MIN AT REST 14 14 5 VOLTS WHILE RUNNING 64 6 4 OHMS MAX RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY SWITCH CLOSES 1104 3 C V LIGHT Q al 9 THE 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 CENTEROF gw PANEL HOUR METER CENTER OF PANEL 90 gt 51 2 4 3 OHMS FRONT LEFT SIDE OF ENGINE 55 OIL PRESSURE THE IGNITION SWITCH WILL NEED TO BE TURNED OFF THEN BACK ON TO RESTART THE ENGINE 1 19 30 32 GROUNDFOR 70A 800RPM 4 708 GROUND 1600 60F 60 OPEN LEAD IS WIRETIED INSIDE THE UNCONNECTED HARNESS BEHIND CONTROL PANEL 7 FOR 1800RPM CONNECT TO FOR LEAVE 54 2 56 PRESSI w G LOVER LEFT OF 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
44. Load 1600 Pipeliner amp 200G K6090 7 46 HP 1600 RPM Low Idle 1360 RATED OUTPUT WELDER DESCRIPTION RATED DC OUTPUT VOLTS RATED AMPS 200 Amp DC Welder Lincoln Plus Rating All Copper Windings 40V 200A Pure DC Power NEMA Rating Generator 28V 200A Displacement Ignition in Ltrs System Delco Voyager High Energy Distributor Type 183 0 3 0 Electronic OUTPUT GENERATOR Auxiliary Power 1 75 kW 15 Amps 120V DC 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 6096 Duty Cycle 100 Amps 34 Volts 60 Duty Cycle 150 Amps 29 Volts 60 Duty Cycle 200 Amps 40 Volts 60 96 Duty Cycle AAA 2 Capacities Fuel 15gal 57L Oil 4 5Qts 4 3L Coolant 9 9 Qts 9 4L DUTY CYCLE DC CURRENT RANGE Fine Adjustment in each Range 40 300 Amps FUEL CONSUMPTION 7 gal hr 2 8 Itrs hr 8 gal hr 3 1 Itrs hr 1 1 gal hr 4 0 Itrs hr 1 04 gal hr 1 12 gal hr 3 94 Itrs hr 4 25 Itrs hr 1 15 gal hr 4 37 Itrs hr 1 34 gal hr PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH 5 07 Itrs hr WEIGHT 40 94 in 24 00 in 1039 9 mm 609 6 mm Top of enclosure add 4 6 116 8mm for exhaust 68 16in 1731 0 mm 1295 0 Ibs 587 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is with
45. SENSED BY ECU FAULTY ECU CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU 610D pp Eg FUSE 15 SELECTOR SWITCH 240 160 GENERATOR LEAD BLOCK SHOWN AS VIEWED WITH ENGINE IN THIS DIRECTION M 90 MIN C 130 80 190 120 x SIDE OF MACHINE REMOTE RECEPTACLE LOCAL REMOTE SWITCH L SHOWN IN LOCAL POSITION SERIES FIELD FJW 5AR COIL PAIR 22 5 5 OHMS EACH INTERPOLE COILS WELDING GENERATOR BRUSH POSITION SHOWN AS VIEWED FROM CONTROL PANEL NEGATIVE OUTPUT TERMINAL 9 TYPICAL WARM MACHINE 88 98 VOLTS AT MAX RHEOSTAT 47 60 VOLTS AT MIN RHEOSTAT UNDER LEFTDOOR PROPRIETARY amp CONFIDENTIAL DESIGNINFORMATION J REFERENCE EQUIPMENT TYPE UNLESS PECIFIED TOLER MANUFACTURING TOLERANCE PER E2 EGRI 056 ALL ANGLES OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING NA POSITIVE OUTPUT TERMINAL WIRE TIED UP BEHIND LOCAL REMOTE SWITCH ON RIGHT SIDE OFMACHINE AS VIEWED FROM CONTROL PANEL LEAD COLOR CODE COMPONENT VALUE UNITS B BLACK OR GRAY G GREEN O ORANGE R RED OR PINK U BLUE W WHITE Y YELLOW LABELS COMMON 7 FRAME GROUND EARTH GROUND DRAWN BY DM L12020 ENGINEER
46. UPPER LEFT FORTION OFCONTROL PANEL SENSOR GROUNDS LEAD ON SENSE OF WELD OR AUXILIARY LOAD CURRENT SENSING PC BOARD SCHEMATIC 525973 61 N DRIVER BRUSH POSITION SHOWN AS VIEWED FROM CONTROL PANEL THESE LEADS MUST ROUTED THRU CURRENT SENSOR IN SAME CURRENT FLOW DIRECTION AS SHOWN LOMER LEFTOF CONTROL PANEL o 720C RHEOSTAT 644 64 OHMS MAX 730 DC AUXILIARY RECEPTACLE GND T J8 77 Y P9 JUMPER PLUG IS WIRE TIED UP BEHIND LOCAL REMOTE Y SWITCH ON RIGHT X i CIRCUITS 12 SUPPLY 7 LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE CORRECTIVE MEASURE LONG 1 SHORT 1 RPM IS OVER 115 OF RATED RPM 2070 RPM ACTUATOR IS STUCK REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED LONG 1 SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND 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 LONG 1 SHORT 3 L TERMINAL IS GROUNDED ON ALTERNATOR FOR 1 SECOND BROKEN OR LOOSE BELT INSPECT LEAD TO L TERMINAL ON ALTERNATOR MAY SHORTED TO GROUND CHECK FAULTY ALTERNATOR CHECK LONG 1 SHORT 4 HIGH WATER TEMPERATURE DETECTED FOR 1 SECOND AMOUNT OR QUALITY OF
47. WK to case ground This is a normal With engine running the resistance from termi nal G to case ground should be as follows 140F equals approximately 134 ohms 194F equals approximately 51 ohms 212F equals approximately 39 ohms ly open switch and should read a very high 7 Replace the two leads previously removed resistance 4 This switch should close at approximately 230F This over temperature condition would shut off the engine 5 Using the ohmmeter check the resistance from terminal G to case ground At room tempera ture this resistance should be approximately 520 ohms PIPELINER 200 LINCOLN 32 5 PIPELINER 200 LINCOLN amp F 32 901 J91Se N DOL J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL DOL uonoes DOL TROUBLESHOOTING 8 REPAIR pus CURRENT SENSOR PCB TEST A 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 Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are
48. 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 build up and produce a DC output voltage This DC is applied via the field rheostat control to the main gen erator shunt field coils The exciter output is also con nected to the 120VDC receptacle MAIN SHUNT INTERPOLE amp SERIES COILS 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 con nected 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 arma ture POSITIVE OUTPUT TERMINAL ENGINE MAIN GENERATOR ARMATURE FRAME amp DC EXCITER CURRENT RANGE SELECTOR The selector switch acts as a course current adjust ment 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 cur rent adjustment by controlling the current throug
49. a miss 2 Unlatch and secure the right side door ing spring Locate the idler solenoid and the two leads with 8 the linkage is intact and the solenoid does not 9 quick connects See Figure 4 operate correctly when 12VDC is applied the idler x 4 Disconnect the two solenoid leads at the quick con solenoid may be faulty Replace the idler solenoid nection splices NOTE Normal solenoid coil resistance is approxi 5 Using the external power supply apply 12VDC to mately 9 ohms the idler solenoid leads The solenoid should acti After the test and repairs are completed close and vate latch the right side door 6 The solenoid should deactivate when the 12VDC is removed Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC 2 8 5 19 TROUBLESHOOTING amp REPAIR MAIN GENERATOR SHUNT FIELD WINDING TEST A 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 safe
50. 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 1 In the High position the idler solenoid acti vates and the engine goes to high idle speed The speed is controlled by the governor 2 In the Auto lt gt position the idler oper ates as follows 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 O10 5
51. 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 Section TOC Return to Master 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will magnetize the exciter pole pieces 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 Return to Section TOC Return to Master TOC O10 5 10 9 1 0 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN ean TROUBLESHOOTING amp REPAIR FLASHING THE FIELDS continued FIGURE F 7 EXCITER COVER REMOVAL Return to Section TOC Return to Master TOC 8 18 s 513 FEE 4 gt 27 2 3 COVER a PROCEDURE 1 Turn the engine OFF 2 Using a 3 8 Nutdriver remove the exciter cover See Fi
52. blower paddles and 2 wood or steel blocks the armature to the engine flywheel 8 2 6 Using the 5 8 wrench remove the eight bolts 5 and lock washers holding the blower paddles 515 and the armature to the engine flywheel See 2 Perform other replacement procedures c Figure F 28 according to each of the following 7 With the armature supported and balanced Generator Frame Removal in the rope sling carefully rotate the armature Replacement 1 8 turn in either direction to release it DC Armature Removal CAUTION The armature is now free to be removed from the engine Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B Pod TROUBLESHOOTING amp REPAIR pod 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 machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC ENGINE OUTPUT Engine Mode No Load RPM Load RPM Perkins Low Idle 1375 1425 NA Perkins High Idle 1540 1650 1450 1600 Kubota Low Idle 1390 1410 NA Kubota High Idle 1580 1600 1550 1600 GM Gas Low Idle 1340 1360 NA GM Gas High Idle 1580 1600 1550 1600 Return to Section TOC Return to Master TOC WELDER DC OUTPUT Current Control Current Selector Open Circuit Load Volts Load Amps
53. cable to the new battery last b Connecting a battery charger remove the bat tery from the welder by disconnecting the neg ative 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 if you have an ignition switch turn it off when engine is not run ning To prevent BATTERY BUCKLING tighten nuts on battery clamp until snug The Pipeliner amp 200D is equipped with a wet charged battery The charging current is automatically regulat ed 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 2000 PERKINS LINCOLN B 5 ADS PIPELINER 200D PERKINS LINCOLN amp AA 6 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes TABLE 5 OPERATION SECTION o O Lr 5
54. doors assembly to the welder frame Install the rubber gasket to the top 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 PIPELINER 200 LINCOLN B F 59 MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE 60 5 PIPELINER 200 LINCOLN amp F 60 DOL J91Se N 01 DOL J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL DOL uonoes DOL Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC 2 8 5 61 TROUBLESHOOTING 8 REPAIR MAIN GENERATOR ARMATURE REMOVAL AND REPLACEMENT PROCEDURE A 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 If for any reason you do not understand the test procedures or are una
55. 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 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 ADJUSTMENT A Potentiometer is mounted on the Control Panel that allows the operator to adjust the high idle engine speed between 1450 and 1600 This is to allow further adjustment of the 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 2000 KUBOTA LINCOLN B Return to Section Return to Master TOC Return to Section TOC olo o Fle 9 1 gt 812 cfc 515 pie oO oO Return to S
56. manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN 8 PIPELINER 200 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio E ojeg 3 O0 9 512 clo Return to Section TOC Return to Master TOC G 4 ELECTRICAL DIAGRAMS WIRING DIAGRAM CODE 10929 M20056 GLOW PLUGS la START EC ria A N HOUR METER D o 1 56A 60 STARTING MOTOR GROUND GROUND TO BASE TO ENGINE PIPELINER 200D WIRING DIAGRAM EXCITER BRUSHES SHOWN AS VIEWED FROM CONTROL PANEL NAV ENGINE FAILURE LAMP 1234567891 IDLER ENGINE J1 PROTECTION P C BOARD 60C 57 IDLER SWITCH 56 4 SOLENOID 29 IGNITION GND B SWITCH PUMP SOLENOID d ra 212 58 cae FUEL PUMP 540 SWITCH SENDER OIL PRESSURE O OJ SWITCH SENDER G TEMPERATURE GROUND SCREW NEAR ENGINE GUAGES THESE LEADS MUST BE ROUTED THRU CURRENT SENSOR IN SAME CURRENT FLOW DIRECTION AS SHOWN K924 5 REMOTE CONTROL OPTIONAL x PLUG FOR REMOTE CONTROL POTENTIOMETER CONNECT TO CASE RESISTORS REMOTE CONTROL POTENTIOMETER BOX LEAD COLOR CODE ELECTRICAL SYMBOLS PER E1537 B BLACK OR R RED OR GRAY G GREEN N
57. 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 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 WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground 5 8 GASES be dangerous Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone 7 WELDING SPARKS can cause fire explosion Keep flammable material away ARC RAYS can burn Wear eye ear and body protection 12 DUTY CYCLE The NEMA output rating of the PIPELINER amp 200D KUBOTA is 200 amperes at 28 arc volts on a 6096 duty cycle consult Specifications in this manual for alternate ratings Duty cycle is based on a ten minute period thus the
58. 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 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 elec tronic controller is programmed to automatically com pensate 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 gover nor will correct itself for the new operating conditions and normal operation will resume OPERATION BBB 4 IDLER OPERATION The operating speeds are as follows ORDERING FULL HIGH LOW INFO LOAD IDLE IDLE K6090 7 GM 3 0L 1600 1600 1360 1500 1500 The idler is controlled by the Idler toggle switch on the welder control panel The switch has two positions as follows
59. 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 pres sure air Arcing or excessive exciter brush wear indicates a pos sible misaligned shaft an authorized Field Service Shop check and realign the shaft IDLER MAINTENANCE CAUTION Before doing electrical work disconnect the bat tery When installing a new battery or using a jumper battery to start the engine be sure the battery polarity is con nected properly The correct polarity is negative ground Damage to the engine alternator and the Engine Control Unit can result from incorrect connec tion 1 Proper operation of the idler requires good ground ing of the Engine Control Unit current sensing printed circuit board and battery 2 If desired the welder can be used without automat 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 SYSTEM KUBOTA V2203M ENGINE A 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 c
60. the leads from the idler switch See Figure F 22 and the Wiring Diagram Remove leads from the Idler Solenoid See Wiring Diagram PIPELINER 200 LINCOLN olo MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED 8 2 FIGURE 22 FRONT PANEL WIRING CONNECTIONS 2 E IDLER PC BOARD tc IDLER SWITCH TO IDLER SWITCH 010 Q EN IGNITION SWITCH ZA 2190 Sb 8 8 oR N S LEADS TO AMMETER ele START BUTTON SHUNT LEADS gt QUICK DISCONNECT A DC RECEPTACLE FB TROUBLESHOOTING amp REPAIR poo MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 23 FRONT PANEL FASTENER REMOVAL Return to Section TOC Return to Master TOC BOLTS NUTS WASHERS 2 o MIDDLE SCREW 1 j BASE MOUNTING BOLTS 4 23 Using the 1 2 wrench remove the two bolts 25 Using the 3 8 nut driver remove the screw nuts and washers that hold the front panel from the lower middle of the front panel See assembly to the horizontal rails There is Figure F 23 one on each side See Figure F 23 Return to Section TOC Return to Master TOC 26 Carefully remove the front panel assembly 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 O10 5
61. to reset the engine protection system 7 Allow the engine to run at high idle speed for sever al 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 prop erly set at the factory and should require no adjust ing when received OPERATION BB 3 COLD WEATHER STARTING 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 day s 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 dis tribution system If this happens bleeding of the fuel
62. unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting 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 Return to Section TOC Return to Master TOC O10 5 10 9 1 0 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC ke 2 8 5 34 TROUBLESHOOTING amp REPAIR CURRENT SENSOR PCB TEST CONTINUED FIGURE F 11 CASE COVERS PROCEDURE Turn the engine off Remove the four nuts and bolts holding the case top and doors assembly to the welder frame See Figure 11 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 Turn the engine on and record the voltage between pins 1 and 2 of J1 Wiring Diagram This voltage should be approximate ly 12 VDC batte
63. welder can be loaded at rated output for six minutes out of every ten minute period CONTROL OF WELDING CURRENT CAUTION WHILE WELDING because current may arc between the contacts and damage the switch The Current Range Selector provides five overlap ping 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 pre ferred 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 posi tion and the Fine Current Adjustment setting to get 175 amps Some arc instability may be experienced with EXX10 electrodes when try
64. 14 145 VOLTS 77 WHILE RUNNING 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 STARTER RELAY BEHIND CONTROL PANEL 64 6 4 OHMS MAX HARNESS BEHIND CONTROL PANEL FOR 1800RPM DC EXCITER 1 777 DC USES RESIDUAL SHUNT FIELD MAGNETISM TO FLASH 209 IDLER SWITCH SHOWN IN AUTO FDW 5M EXCITER COIL SHUNT COIL WINDINGS ARE 65 1 5 OHMS EACH SERIES COIL WINDINGS ARE 143 005 OHMS EACH gt gt WIRE TIED TO HARNESS gt gt THE P10 PLUG IS ONLY ON UNITS WITHOUT p10 K924 5 REMOTE CONTROL OPTIONAL REMOTE CONTROL PLUG G 25 1 25 OHMS EACH RHEOSTA REMOTE NTROL BOX FLYBACK DIODE PREVENTS VOLTAGE SPIKES IN SHUNT FIELD FROM DAMAGING LOCAL REMOTE TOGGLE SWITCH WHEN SWITCHED THE WIRE FEED MODULE THE WIRE FEED MODULE HAS A HARNESS THAT PLUGS DIRECTLY INTO 15 JUMPER PLUG IS IDLE POSITION SERIES FIELD LOCATED BEHIND
65. 8 TO EXCITER OUTPUT PARTS SUPPLIED L WITH ENGINE ENGINE HOUR METER 600A SELECTOR Pd SWITCH SWITCH FOR LOCAL OR IGNITION AY REMOTE CONTROL SHOWN SWITCH IATER TEMP SENDER IN di QH SENSOR 44 WELDER LEAD BLOCK IN LOCAL POSITION Return to Section TOC Return to Master TOC CURRENT OIL PRESS CONTROL PANEL 6 THESE LEADS MUST ROUTED THRU 4 GROUND SCREW CURRENT SENSOR IN THE SAME SENSOR CURRENT FLOW DIRECTION AS SHOWN U GROUND GROUND NEGATIVE 9 M POSITIVE TO ENGINE TO BASE CC CC amp CV WITH W F M K924 5 REMOTE CONTROL OPTIONAL WIRE FEED MODULE OPTIONAL ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 PLUG P5 ON W F M TO CONNECTOR J5 ON MACHINE PLUG uri x PLUGFOR CONTROL REMOTE CONTROL POTENTIOMETER INLINE CONNECTORS eio E ojeg 3 O0 1 c 512 amp c WIRE FEED i NEGATIVE MODULE TERMINAL REMOTE CONTROL POTENTIOMETER 57 BRUSH HOLDER 2 HEAVY LEAD 200 AMP THERMOSTAT MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS Return to Section TOC Return to Master TOC L11864 NOTE This diagram is for reference only It may not be accurate for all machines covered by this
66. 88 935 3877 PIPELINER 200 LINCOLN B Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 5 Return to Section Return to Master TOC 2 0 8 5 TROUBLESHOOTING amp REPAIR dis Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S 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 The engine cranks but will not start OUTPUT PROBLEMS 1 Check the auxiliary power plug and associated leads for loose or faulty connections 2 The load may be too small The load must be above 150 watts 1 Make sure the ignition switch is in the ON position 2 Check for adequate fuel supply 1 Check the idler control switch and associated leads for loose or faulty connections See the Wiring Diagram Check the CURRENT SENSING PC BOARD Perform the Current Sense Board Test Replace if necessary Perform the dler Solenoid Test PERKINS 10929 Check f
67. ADS MUST BE ROUTED THRU CURRENT SENSOR IN SAME CURRENT FLOW DIRECTION AS SHOWN LOWER LEFT OF CONTRO PANEL T3 RHEOSTAT 64 6 4 OHMS MAX CONTRA PANEL DC AUXILIARY RECEPTACLE 77 CIRCUITS 12 SUPPLY AUXILIARY LOAD 842 lis 7 LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE CORRECTIVE MEASURE LONG 1 SHORT 1 RPM IS OVER 115 OF RATED RPM 2070 RPM ACTUATOR IS STUCK REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED LOW OIL CHECK OIL LEVEL ON DIPSTICK LONG 1 SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND FAULTY OIL PRESSURE SWITCH CHECK THAT WK STUD IS OPEN WHEN ENGINE IS RUNNING LEAD TO OIL PRESSURE SWITCH STUD BE GROUNDED CHECK LONG 1 SHORT 3 L TERMINAL IS GROUNDED ON ALTERNATOR FOR 1 SECOND BROKEN OR LOOSE BELT INSPECT LEAD TO L TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND CHECK FAULTY ALTERNATOR CHECK LONG 1 SHORT 4 SECOND HIGH WATER TEMPERATURE DETECTED FOR 1 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 LONG 1 SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 SHORT 1 FROM 0 RPM IS DETECTED AND 12V IS DETEC
68. ALTERNATOR FOR 1 SECOND LEAD TO L TERMINAL ON ALTERNATOR MAY BE OPEN CHECK FOR CONTINUITY BROKEN OR LOOSE BELT INSPECT FAULTY ALTERNATOR CHECK LONG 2 SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR INCORRECT BATTERY INSPECT FAULTY ALTERNATOR CHECK LONG 2 SHORT 8 LESS THAN 4 VOLTS TO RPM SENSOR AND OR ACTUATOR SENSED BY ECU FAULTY ECU CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU NEGATIVE OUTPUT TERMINAL TYPICAL OCV WARM MACHINE 88 98 VOLTS AT MAX RHEOSTAT 47 60 VOLTS AT MIN RHEOSTAT UNDER LEFT DOOR PROPRIETARY amp CONFIDENTIA MANUFACTURING TOLERAN UNLESS OTHERWISE SPECIFIED TOLERANCE ON 2 PLACE DECIMALS IS 02 in 0 5 mm ON 3 PLACE DECIMALS IS 002 in 0 05 mm DRAWNBY Maglietta ic PRINTED ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING POSITIVE OUTPUT TERMINAL CONTROL CLEVELAND SCALE EQUIPMEN TYPE LEAD COLOR CODE B BLACK OR GRAY G GREEN R RED OR PINK U BLUE W WHITE Y YELLOW N BROWN LABELS x COMMON 77 FRAME GROUND EARTH GROUND Li THis DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY BE DUPLICATE TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC PIPELINER 200D KUBOTA WIRETIED UP BEHIND SIDE OF MAQHI
69. ANEL STARTRELAY 212D IGNITION 55 SWITCH 51B ELECTRICAL DIAGRAMS PIPELINER 200D WIRING DIAGRAM CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR LEADS CONNECTED TO ENGINE CONTROL UNIT SEE DETAIL NOTE LEAD 70A IS LEFT OPEN AND WIRE TIED INTO HARNESS 57 ACTUATOR ENGINE 56 0 FAILURE LAMP ENGINE HOUR METER 61 6 o 841A O1 58 7 841 EXCITER BRUSHES SHOWN AS VIEWED FROM CONTROL PANEL SERIES RPM CONTROL TEMP SWITCH 29 34 BATTERY ALTERNATOR OIL PRES SWITCH SENDER 4 09 200 WRG PRESSURE GAUGE WATER ENGINE TEMP SPEED SENSOR SENSOR LEAD COLOR CODE B BLACK OR R RED OR GRAY PINK G GREEN U BLUE N BROWN W WHITE Y YELLOW SWITCH FOR LOCAL OR SELECTOR REMOTE CONTROL SHOWN SWITCH IN LOCAL POSITION GENERATOR LEAD BLOCK SHOWN AS VIEWED WITH ENGINE IN THIS DIRECTION es SERIES 43 844 GROUND GROUND 842 GROUND SCREW NEAR IDLER SWITCH ENGINE GAUGES K924 5 REMOTE CONTROL OPTIONAL PLUG FOR REMOTE CONTROL POTENTIOMETER Bre i REMOTE CONTOL 27 RESISTORS NEGATIVE POSITIVE CC amp CV WITH W F M THESE LEADS MUST BE ROUTED THRU CURRENT SENSOR IN SAME CURRENT FLOW DIRECTION AS SHOWN WIRE FEED MODULE OPTIONAL INLINE C
70. BROWN SHUNT CONTROL PANEL COMPONENTS PINK SHOWN AS VIEWED FROM REAR P10 U BLUE W WHITE J5 Y YELLOW RECEPTACLE 9 830 9 SERIES 730A NEGATIVE INLINE CONNECTO CONTROL PANEL CONNECT TO POS amp OUTPUT TERMINALS GROUND SCREW NEAR FUSE 720A 602 RHEOSTAT 600A SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION SELECTOR SWITCH GENERATOR LEAD BLOCK SHOWN AS VIEWED WITH ENGINE IN THIS DIRECTION SERIES POSITIVE amp 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 RS NEG f O Pos WIRE FEED NEGATIVE PANEL CONNECT TO NEG BRUSH HOLDER Noche MODULE 2 HEAVY LEAD 250 AMP THERMOSTAT ASSEMBLY MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS 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 LINCOLN 8 PIPELINER 200 0 5 ELECTRICAL DIAGRAMS WIRING DIAGRAM CODE 11114 11316 20464 PIPELINER 200D WIRING DIAGRAM ENGINE CONTROL UNIT CONNECTOR DETAIL CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR LEAD COLOR CODE k LEADS CONNECTED TO ENGIN
71. CAL REMOTE 4 SWTCH CN RIGHT SIDEOF MACHINE AS W VIEWED FROM CONTROL PANEL LOCAL REMOTE 9 9 SWITCH SHOWN IN LOCAL POSITION REMOTE LOCATED BEHIND UPPER RECEPTACLE PORTION CF OONTROL PANEL SENSOR GROUNDS LEAD TO IDLER ENGINE PROTECTION ENGINE IN THIS DIRECTION BOARD ON SENSE OF WELD OR AUXILIARY LOAD CURRENT SENSING PC BOARD SELECTOR SWITCH 90 MIN OM FJW 5AR PAIR LEAD COLOR CODE yer CIRCUITS 22 5 5 OHMS EACH GRAY 190 120 77 G GREEN INTERPOLE GENERATOR LEAD BLOCK SHOWN AS VIEWED WITH ke 5 o gt 2 GE C He 42 8 E tc SERIES FIELD COMPONENT VALUE UNITS CAPACITOR MFD VOLTS RESISTOR OHMS WATTS 240 160 32 O ORANGE 12 VOLT SUPPLY COILS R RED OR PINK U BLUE 3 TURNS W WHITE Y YELLOW CONNECTOR PIN NUMBERS EX 12 PIN CONNECTOR 12 6 WELDING m GENERATOR 5 COMMON Due 7 12 77 FRAME GROUND LATCH L EARTH GROUND VIEW OF CONNECTOR ON PC BOARD THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY 8 CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN
72. DJUSTMENT S The engine AND starts but runs only about 30 60 seconds and shuts down The welding arc is loud and spatters excessively The welding arc frequently pops out WELDING PROBLEMS Make sure the correct grade and amount of oil is in the engine crankcase See the Maintenance Section of this manual Make sure the engine is not overheating Make sure the engine alternator is operating properly The current setting may be too high for the electrode and process The polarity may be wrong for the electrode and process The fine current control field rheostat may be set too low for the process and electrode Check the welding cables for loose or faulty connections F 10 RECOMMENDED COURSE OF ACTION 1 The oil pressure switch may be faulty Perform the Oi Pressure Switch Test 2 The Temperature Switch may be fault Perform the Temperature Switch Test The alternator may be faulty Perform the The 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 Check the engine speed High idle speed should be 1800 RPM If Necessary Check the main DC generator brushes for good commutation and alignment Contact the Lincoln Electric Service Dept at 1 888 935 3877 Check the e
73. 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 K924 5 REMOTE CONTROL OPTIONAL REMOTE CONTROL PLUG 25 1 25 OHMS EACH CONTROL BOX OIL PRESSURE SWITCH SENDER CONTRO PANEL SWITCH CLOSES SENDER OPERATION AT 6 2 PSI 0 PSI gt 10 5 OHMS 40PSI gt 105 5 OHMS 80 PSI gt 187 5 OHMS STARTER RELAY DC EXCITER oe DC EXCITER USES RESIDUAL MAGNETISM TO FLASH IDLER SWITCH SHOWN IN AUTO IDLE POSITION NCC SHUNT FIELD TOE FDW 5M EXCITER COIL SHUNT COIL WINDINGS ARE 65 1 5 OHMS EACH SERIES COIL WINDINGS ARE 143 005 OHMS EACH gt gt gt gt THE P10 PLUG IS ONLY ON UNITS WITHOUT THE WIRE FEED MODULE THE WIRE FEED MODULE HAS A HARNESS THAT PLUGS DIRECTLY INTO J5 WIRETIED TO HARNESS BEHIND CONTROL PANEL JUMPER FLUG IS LOCAL REMOTE SWITCH ON RIGHT VIEWED FROM SERIES FIELD LOCATED BEHIND UPPER LEFT PORTION OF CONTROL PANEL SENSOR GROUNDS LEAD CURRENT SENSING SCHEMATIC 525973 610C BRUSH POSITION SHOWN AS VIEWED FROM CONTROL PANEL PC BOARD ON SENSE OF WELD OR t MH THESE LE
74. E CONTROL UNIT SEE DETAIL B BLACK OR R RED OR NEUTRAL BONDED TO FRAME GRAY EINK G GREEN U BLUE NEUTRE RACCORDE AU N BROWN WAWHITE NOTE LEAD 70A IS LEFT Y YELLOW OPEN AND WIRE TIED INTO HARNESS EXCITER BRUSHES SHOWN AS VIEWED FROM CONTROL PANEL 57 2 ACTUATOR SHUNT 56 WIRE TIED TO WIRING FAILURE 0 7 START HARNESS BEHIND LAMP _ ENGINE HOUR METER CONTROL PANEL RECEPTACLE 9 600 61 06 9 81 58 22 52B 70C e 70B 1 STARTRELAY 45 55 Mo 730A e GND T RPM CONTROL 52 IGNITION 55 SWITCH SWITCH 841B TEMP GROUND SCREW NEAR FUSE o 720A 54B 5 7 Return to Section Return to Master TOC 51A Return to Section TOC Return to Master TOC OIL PRES z SWITCH 5 SELECTOR SWITCH FOR LOCAL OR 50A SENDER REMOTE CONTROL SHOWN 54 9 5 200 SWITCH IN LOCAL POSITION L GENERATOR LEAD BLOCK PRESSURE SHOWN AS VIEWED WITH GAUGE 1 ENGINE IN THIS DIRECTION ALTERNATOR WATER ENGINE TEMP SPEED BATTERY 5 SENSOR SENSOR LE 67 GROUND GROUND 60 GND B o 0 844 NEGATIVE POSITIVE ENGINE GROUND SCREW NEAR THESE LEADS MUST BE ROUTED THRU ENGINE GAUGES CURRENT SENSOR IN SAME CURRENT FLOW DIRECTION AS SHOWN K924 5 REMOTE CONTROL OPTIONAL WIRE FEED MODULE OPTIONAL
75. ECTION AND AT 6 2 PSI 0 PSI gt 10 5 OHMS Return to Section TOC Return to Master TOC ALTERNATOR FLASHING DELAY IMER LOGIC UPON RECIEVEING POWER CIRCUIT TO FLASH ALTERNATOR IS OPENED AND ENGINE PROTECTION IS BYPASSED AFTER TIME DELAY ALTERNATOR FLASHING Q2 ON FOR HIGH IDLE DC EXCITER IDLER SWITCH ers SHOWN IN AUTO IDLE POSITION SHUNT FIELD 40PSI gt 105 5 OHMS 80 PSI 187 5 OHMS FDW 5M EXCITER COIL SHUNT COIL WINDINGS ARE 65 1 5 OHMS EACH SERIES COIL WINDINGS ARE 143 005 OHMS EACH JUMPER PLUG IS FOR CONNECTION TO WIRE FEED MODULE P10 FLYBACK DIODE PREVENTS VOLTAGE SPIKES IN SHUNT FIELD FROM DAMAGING LOCAL REMOTE TOGGLE SWITCH WHEN SWITCHED JUVPER PLUG IS WRE TIED UP BEHIND LOCAL REMOTE CIRCUIT IS CLOSED AND ENGINE PORECTION 15 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 SWITCH CN RIGHT SIDEOF MACHINE AS VIEWED FAM CONTRA PANEL 20 IY SERIES FIEL RHEOSTAT 64 6 4 OHMS MAX BRUSH POSITION SHOWN VIEWED FROM CONTROL PANEL DC EXCITER USES RESIDUAL MAGNETISM TO FLASH DC AUXILIARY RECEPTACLE 7 77 JUVPER PLUG IS WRE TIED UP BEHIND LO
76. For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master 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 trou bleshooting assistance before you proceed Call 1 888 935 3877 e DESCRIPTION 5 5 This procedure will aid the technician the removal and replacement of the DC z 9 generator frame DE 2 5 5 MATERIALS NEEDED a e 2 c 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 O10 5 10 9 1 0 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN FoU TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 16 BATTERY PANEL REMOVAL Return to Section TOC Return to Master TOC Ze LM 9 o o 9 5 5 5184 lz 2 212 PROCEDURE 1 Turn the engine OFF 3 Using the 1 2 wrench remove the negative battery cable 2 Using the 7 16 wrench remove the two bolts and washers and partially slide out the battery mounting panel See Figure F 16 ojo o Fi
77. GLOBAL ING UNLESS OTHERWISE SPECIFIED TOLERANCE 3 MANUFACTURING TOLERANCE PER E2056 REFERENCE EQUIPMENT TYPE PIPELINER 200D 0 DRAWN JRS ON ALL ANGLES IS 5 OF DEGREE SUBJECT MATERIAL TOLERANGE 1 TOAGREE ENGINEER 85 MACHINE SCHEMATIC WITH PUBLISHED STANDARDS MATERIAL yp APPROVAL PROJECT 33528 DO NOT SCALE THIS DRAWING DISPOSITION DATE 12 09 2002 NUMBER THESE LEADS MUST BE ROUTED THRU CURRENT SENSOR IN SAME CURRENT FLOW DIRECTION AS SHOWN BRUSH POSITION SHOWN AS VIEWED FROM CONTROL PANEL NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL TYPICAL OCV WARM MACHINE 88 98 VOLTS AT MAX RHEOSTAT 41 60 VOLTS AT MIN RHEOSTAT Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual PIPELINER 200 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC eio E ojeg 3 O0 9 5153 5 clo Return to Section TOC Return to Master TOC Return to Master TOC G 8 ELECTRICAL DIAGRAMS SCHEMATIC COMPLETE MACHINE CODE 11114 11316 L12362 296211 RATED VOLTAGE 12V RATED CURRENT 22mA MAX SPEED SENSOR OPERATION gt 18 80 KOHMS 104 gt 1 14 5 212W 16 KOHMS RATED VOLTAGE 12V RATED CURRENT 2A COIL RESISTENCE
78. HORT 3 L TERMINAL IS GROUNDED ON ALTERNATOR B FOR 1 SECOND LEAD TO L TERMINAL ON ALTERNATOR MAYBE HORTED TO GROUND CHECK FAULTY ALTERNATOR CHECK LONG 1 SHORT 4 HIGH WATER TEMPERATURE DETECTED AMOUNT OR QUALITY OF COOLANT INCORRECT FOR 1 SECOND CHECK FAULTY WATER TEMPERATURE SWITCH CHECK THAT WK STUD IS OPEN WHEN ENGINE IS NOT RUNNING LEAD TO WATER TEMPERATURE SWITCH MAY BE ROUNDED CHECK 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 IO RPM SENSOR FROM E 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 LONG 2 SHORT 3 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 SHORT 4 50C WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR CHECK FOR LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN CHECK FOR CONTINUITY LONG 2 SHORT 5 150 WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR CHECK FOR PROPER RESISTANCE LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED CHECK LONG 2 SHORT 6 0 VOLTS DETECTED FROM L TERMINAL ON LEAD TO L TERMINAL ON ALTERNATOR MAY BE OPEN ALTERNATOR FOR 1 SECOND FAULTY ALTERNATOR CHECK LONG 2 SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR INCORRECT BATTERY INSPECT FAULTY ALTERNATOR CHECK LONG 2 SHORT 8 LESS THAN 4 VOLTS TO RPM SE
79. INER 200 LINCOLN Return to Section Return to Master TOC Return to Section TOC O10 5 10 9 1 0 lz 813 pir oO oO ayo Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 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 pos sible symptoms that the machine may exhib it 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 con tribute to the machine symptom Perform these tests checks in the order listed n general these tests can be conducted with out re
80. KUBOTA is equipped with a wet charged battery The charging current is automat ically 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 Return to Section TOC Return to Master TOC PIPELINER 200D KUBOTA LINCOLN B Return to Master TOC Return to Master TOC o He 9 5 Return to Master 85 TABLE OF CONTENTS OPERATION SECTION 57 Sure 1 Engine Operation 2 Welder Operation seis risd B 3 Idler Operation ER I B 4 PIPELINER 2000 KUBOTA LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC ojo O o Fie 5 5 8 R7 9 1 0 gt 813 oO oO r Return to Section TOC Return to Master TOC Return to Master TOC a OPERATION WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance inst
81. Master TOC Ed THEORY OF OPERATION EMT FIGURE E 4 ENGINE CONTROL IDLER ENGINE PROTECTION P C BOARD ENGINE FROM CURRENT SENSING P C BOARD METER SOLENOID PERKINS DIESEL ENGINE BATTERY STARTER ENGINE ALTERNATOR OIL amp TEMPERATURE SWITCH CIRCUITS 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 con trol and protection modules monitor engine oil pres sure coolant temperature and engine RPM The sys tem shuts the engine down in the event of a sudden low oil pressure or high coolant temperature A warn ing light on the control panel provides fault codes or on some models the engine fault light will glow 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 con trol protection being used COUPLED TO GENERATOR When the welding or auxiliary load is removed a preset time delay of about 15 seconds starts After approxi mately 15 sec
82. NE AS 9 A2 SIZE SUBJ NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual MACHINE SCHEMATIC UNITS MATERIAL APPROVAL PROJECT REFERENCE INCH 11 16 2007 CRM37569 112362 FLYBACK DIODE PREVENTS VOLTAGE SPIKES IN SHUNT FIELD FROM DAMAGING LOCAL REMOTE TOGGLE SWITCH WHEN SWITCHED COMPONENT VALUE UNITS CAPACITOR MFD VOLTS RESISTOR OHMS WATTS CONNECTOR PIN NUMBERS EX 12 PIN CONNECTOR 12 6 000000 TN 12 LATCH VIEW OF CONNECTOR ON PC BOARD OMMUNICATED PAGE 1 1_ DOCUMENT REVISION A PIPELINER 200 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio E ojeg Of c 512 2 c Return to Section TOC Return to Master TOC G 10 ELECTRICAL DIAGRAMS SCHEMATIC CURRENT SENSE PC BOARD CODE 10929 11114 11316 11471 525973 6 6665 LINCOLN 8 SDATAA THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIPMENT TYPE CLASSI C SERI ES
83. NECTED 60F 60E JUMPER PLUG IS BEHIND LOMER RIGHT SIDE OFCONTROL PANEL gt 1 gt 2 4 LOMER RIGHT OF CONTROL PANEL RPM CONTROL POTENTIOMETER 10 000 1 000 OHMS TURN POT COUNTERCLOCKWISE TO REDUCE RESISTANCE AND SUBSEQUENTLY REDUCE RPM BY UP TO 150RPM BACK LEFTSIDE OFENGINE ALTERNATOR 40 12 VOLT 64 SENSES ALTERNATOR OUTPUT FLASHES ALTERNATOR 212E IGNITION SWITCH AMMETER SHOWS FULL DISCHARGE WHILE PRESSING GLOW PLUG BUTTON GLOW PLUG SWITCH 9202 59 GLOW PLUGS TYPICAL CURRENT DRAW IS 40 AMPS 40 TO 40 5 AMMETER SHOWN IN OFF POSITION BACK LEFT SIDE 21 5 1 4 oo 43 841 w G TEMPERATURE SWITCH SENDER SWITCH CLOSES 230W 6 F SENDER 194 gt 51 212 F gt 38 5 3 OHMS FRONT LEFT SIDE G TEMPERATURE GAUGE LOWER LEFTOF PERATION 2128 CONTROL PANEL 140 F gt 134 13 5 OHMS 2 4 3 OHMS SENDER IS APPROX 500 OHMS AT 70F 200 855 PRESSURE un WK G OIL PRESSURE SWITCH SENDER SWITCH CLOSES SENDER AT 6 2 PSI GAUGE G LOVER LEFTOF CONTROL PANEL PERATION 0 PSI gt 10 5 OHMS 40PSI gt 105 5 OHMS 80 PSI gt 187 5 OHMS B BACK BOTTOM 50 d STARTER 5 SOLENOID BATTERY STARTER 12 6 VOLTS MIN MOTOR ATREST
84. NSOR AND OR FAULTY ECU CHECK FOR 12 VOLTS ON LEADS TO RPM ACTUATOR SENSED BY ECU SENSOR AND ACTUATOR FROM ECU PIPELINER 200 LINCOLN B 12 5 PIPELINER 200 LINCOLN amp F 12 901 J91Se N 901 J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL DOL uonoes DOL Return to Section Return to Master TOC Return to Section TOC O10 5 10 9 1 0 oO oO Return to Section Return to Master TOC Return to Master TOC F 13 TROUBLESHOOTING amp REPAIR DC EXCITER TEST A 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 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 trou bleshooting 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 oper ation is not correct th
85. OLS MECHANICAL STOP WILL SHUT DOWN THE ENGINE 115 OF RATED SPEED COLOR RED 12 VOLT NORMALLY OFF ENGINE SENSOR I 94 20 93 lt 17 07 WATER TEMP SENSOR BACK LEFT SIDE OF ENGINE BACK RIGHT ACTUATOR RPM ENGINE PROTECTION 60 5 57 12 VOLT SUPPLY 56 18 ELECTRICAL DIAGRAMS ENGINEERING CONTROLLED CHANGE DETAIL New MANUFACTURER No 12 VOLT SUPPLY ENGINE CONTROL UNIT LOCATED BEHIND UPPER PORTION OF CONTRO PANEL RATED VOLTAGE 12V RATED CURRENT 4 5A MAX TERMINAL 15 LEAKAGE CURRENT 10 A MAX TERMINAL 16 2 CONNECTOR DETAIL JUMPER FLUG IS BEHIND LOWER LOVER RIGHT OF CONTROL PANEL RIGHT SIDE OF CONTRO PANEL Rew CONTROL POTENTIOMETER 10 000 1 000 OHMS MAX 25 86 TURN COUNTERCLOCKWISE TO REDUCE RESISTANCE AND SUBSEQUENTLY 53 REDUCE RPM BY UP 150RPM BACK LEFT SIDE OF ENGINE 24 ALTERNATOR 40 AMP 12 VOLT 3 88 SENSES ALTERNATOR OUTPUT FLASHES ALTERNATOR 16 gt 51B 15 2120 212 IGNITION SWITCH AMMETER SHOWS FULL GLOWPLUG DISCHARGE WHILE PRESSING BUTTON GLOW PLUG SWITCH RAW IS 40 AMPS er GLOW PLUGS 51C TYPICAL CURRENT
86. ONNECTORS WFM CONTROL PANEL CONNECT POS amp NEG fo POS ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 CONNECT P5 ON W F M TO CONNECTOR J5 ON MACHINE PLUG P5 WIRE FEED 1 OUTPUT TERMINALS 19 MODULE NEGATIVE CV OUTPUT TERMINAL PANEL CONNECT TO NEG BRUSH HOLDER 250 AMP THERMOSTAT ASSEMBLY MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS 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 6 7 ELECTRICAL DIAGRAMS G7 SCHEMATIC COMPLETE MACHINE CODE 10929 L12020 ENGINEERING CONTROLLED CHANGE DETAIL Released A 01 from X 0202111 IDLER ENGINE PROTECTION PC BOARD LOCATED BEHIND UPPER PORTION CF CONTROL PANEL Be SCHEMATIC L10826 24 gt J13 55 53 ies USED FOR TOROID IN AC 3 AMP CURRENT J2 44 AUXILIARY MACHINES 8 84 88 OHMS IDLE TYPICAL CURRENT 77 RED ENGINE 7 FLYBACK DIODE SOLENOID DRAW IS 1 25 AMPS 51 40 TO 40 AMPS PROTECTION Jt4 ENGINE 57 AAA 56 m AMMETER LIGHT 77 SHUTDOWN 12 NORMALLY OFF cR o IGNITION T SWITCH SHOWN IN OFF O CRI 210A POSITION SOLENOID 7 RUNNING 5 ENGINE 54B Go 54D o TYPICAL CURRENT w G P
87. Order K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp 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 PIPELINER 200G LINCOLN B pep TABLE OF CONTENTS MAINTENANCE SECTION Maintenance uim aru greta 000 1 Safety Precautions gees Fee E e eGo Hehe gt DDD 2 Return to Master TOC Bearings Commutator amp Brushes Idler Control Maintenance DDD 3 Engine Service 222525259 padded res Ese rud ka DDD 4 Major Component Location E p ERR EE das DDD 5 Return to Master TOC o He 9 5 Return to Master PIPELINER 200G LINCOLN B Return to Section Return to Master TOC Return to Section TOC ojo O o Fie 5 5 9 1 o gt 6 1 8 a Return to Section TOC Return to Master TOC Return to Master TOC DDD 2 SAFETY PRECAUTIONS A WARNING Have qualified personnel do the maintenance work Turn the engine off before working
88. PLUG P11 FROM THE REMOTE CONTROL KIT TO CONNECTOR J5 ON CAUTION DAMAGE CAN OCCUR TO THE CONTROL SWITCH IF IT IS USED WITHOUT THE P11 PLUG INSTALLED OR A WIRE FEED MODULE INSTALLED ON PIPELINER 2006 MACHINES CONNECT RED AND BLACK LEADS ON REMOTE RED AND BLACK LEADS ON MACHINE PLUG FOR REMOTE CONTROL POTENTIOMETER Y X CONNECT TO CASE INLINE CONNECTORS WM CONTROL PANEL CONNECT TO POS amp NEG J O POS OUTPUT TERMINALS O NEG a PLUG P5 WIRE FEED NEGATIVE CV OUTPUT TERMINAL PANEL MODULE CONNECT TO NEG BRUSH HOLDER THERMOSTAT ASSEMBLY 2 HEAVY LEAD 200 AMP MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS 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 G 3 WIRING DIAGRAM CODE 10913 11136 L11864 ELECTRICAL DIAGRAMS G 3 PIPELINER aids WIRING DIAGRAM ELECTRICAL SYMBOLS TENTHTHROTTIE RPWCONTRGL PER E1537 CONTROL PANEL COMPONENTS E 5 B BLACKOR U BLUE n 14 CONNECTOR G 1 NEUTRE RACCORDE AU G GREEN sy YELLOW CONNECTOR R RED OR 123458 911121317 PINK Return to Section Return to Master TOC THROTTLE PLATE COIL ALTERNATOR MOTOR
89. R7 9 1 0 gt 2 oO oO Return to Section Return to Master TOC Return to Master TOC Return to Master TOC DED MAINTENANCE 1 Case Front Assembly 2 Engine Assembly 3 Exciter Frame Armature Assembly 4 Generator Frame Armature amp Coupling 5 Fuel Tank Assembly 6 Generator amp Exciter Brush Holder Assemblies 7 Base amp Lift Bale Assembly 8 Radiator Assembly 9 Roof amp Doors Figure DDD 1 Major Component Location PIPELINER 200G LINCOLN B DDD 5 5 PIPELINER 2006 LINCOLN 000 6 901 901 901 01 901 J91Se N DOL DOL uonoes DOL DOL E TABLE CONTENTS THEORY OPERATION SECTION 1 Theory Of Operation Yoel de E E 1 General Description Ev ERR EG E 2 Return to Master TOC Engine MESS MERGER res 3 5 Generator amp obey Be bey ree aues 6 Generator Theory bee E 7 o HF 2 0
90. RETURN TO MAIN MENU SVM193 A July 2009 PIPELINER 200 For use with machines having Code Numbers 11114 11316 11471 10929 10660 10913 11136 Return to Master TOC View Safety Info 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT most importantly think before you act and be careful Return to Master TOC View Safety Info gt 9 5 lt gjo 5 gt SERVICE MANUAL LI NCOLN 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 Return to Master TOC View Safety Info Return to Master Return to Master TOC o Hr 2 0 2 5 Return to Master SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the Sta
91. ROTECTION G TEMPERATURE 5 50A DRAW IS 98 AMPS saree AND GAUGE SENDER OPERATION 2128 oo 52 TEMPERATURE SWITCH SENDER FUEL PUMP 77 CURRENT FLASHING SWITCH CLOSES TYPICAL CURRENT PROTECTION DELAY TIMER 230W 6 F START SWITCH DRAWS 56 AMPS SFE BELOW 212VF gt 38 5 3 OHMS FORLOGIC 5841 0404 4 15 200 OIL PRESSURE 77 Jt5 G G 77 0 OIL PRESSURE SWITCH SENDER IDLER DELAY TIMER CIRUITS SENDER OPERATION K924 5 REMOTE CONTROL OPTIONAL LEFT SDEOF ENGINE AS VIEWED FROM CONTRO PANEL ALTERNATOR 55 AMP 12 VOLT AMMETER SHOWS FULL DISCHARGE WHILE PRESSING GLOW PLUG SWITCH GLOW PLUG SWITCH J2 CONNECTOR 15 NOT USED ON THIS MACHINE REMOTE CONTROL PLUG Return to Section TOC Return to Master TOC GLOW PLUGS TYPICAL CURRENT DRAW IS 40 3 AMPS INJECTION PUMP J1 9 lt 25 COW ww RHEOSTAT MACHINE AS VIEWED FROM CONTRO PANEL 64 6 4 OHMS MAX STARTER SOLENOID gt 1345135 OHMS _ SENDER IS APPROX BATTERY 194 F gt 51 2 4 3 OHMS 500 OHMS AT TOF STARTER r 12 6 VOLTS MIN MOTOR REST 14 14 5 VOLTS GAUGE WHILE RUNNING REMOTE CONTROL BOX HOUR METER SWITCH CLOSES ENGINE PROT
92. Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC 2 8 5 37 TROUBLESHOOTING amp 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 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 trou bleshooting 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 operat ing 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 LINCOLN F 37 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo o Fie 5 5 R7 gt
93. Rheostat Switch Voltage DC AUXILIARY POWER RECEPTACLE OUTPUT Open Circuit Voltage Load Volts 124 138 115 130 15 0 O10 5 9 1 0 gt 813 oO c a FIELD AMPS AND VOLTS Current Rheostat at Maximum Exciter DC Volts Main Shunt Field Amps RPM 128 137 2 10 2 70 1540 1600 Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B 64 5 PIPELINER 200 LINCOLN F 64 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 uunjeH 901 J91Se N 01 DOL uonoes DOL uonoes DOL uonoes DOL uonoes Return to Master Return to Master TOC o He 9 5 Return to Master G TABLE OF CONTENTS DIAGRAM SECTION Electrical Diagrams G 1 Wiring Diagram Code 10660 L11402 4 G 2 Wiring Diagram Code 10913 11136 L11864 1 G 3 Wiring Diagram Code 10929 M20056 2 G 4 Wiring Diagram Code 11114 11316 20464 G 5 Wiring Diagram Code 11471 21564 G 6 Schematic Complete Machine Code 10929 12020
94. TED TERMINAL ON ALTERNATOR FAULTY RPM SENSOR CHECK FOR GOOD CONNECTION 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 610D o o T20C FUSE 15 3 TURNS SELECTOR SWITCH 240 160 GENERATOR LEAD BLOCK SHOWN AS VIEWED WITH ENGINE IN THIS DIRECTION 2 90 MIN 130 80 190 120 X REMOTE RECEPTACLE M SWITCH JUMPER FLUG IS WIRETIED UP BEHIND LOCA REMOTE Y SWITCH RIGHT SIDE OF MACHINE LOCAL REMOTE SHOWN IN LOCAL POSITION SERIES FIELD INTERPOLE COILS FJW 5AR COIL PAIR 22 5 5 OHMS EACH BRUSH POSITION SHOWN AS VIEWED FROM CONTROL PANEL WELDING GENERATOR LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED CHECK LONG 2 SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 4 50 WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR CHECK FOR PROPER RESISTANCE LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN CHECK FOR CONTINUITY LONG 2 SHORT 5 150C WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR CHECK FOR PROPER RESISTANCE LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED CHECK LONG 2 SHORT 6 0 VOLTS DETECTED FROM L TERMINAL ON
95. UM Return to Section TOC Return to Master TOC O volts 20 volts 5 ms Return to Section TOC Return to Master TOC 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 O10 5 10 9 1 0 gt 813 pir oO oO Note Scope probes connected machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN 44 5 PIPELINER 200 LINCOLN Hi F 44 901 J91Se N uunjeH DOL J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC 2 8 5 45 TROUBLESHOOTING 8 REPAIR F 45 DC EXCITER ARMATURE
96. UTY CYCLE 200A 28V 200A 40V 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 OPERATION BBB 2 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 Ignition switch Idler control switch hour meter a battery charging ammeter an oil pres sure gauge and engine coolant temperature gauge The control panel also contains a three prong ground ing type receptacle for auxiliary power Welding Generator The Pipeliner amp 200G uses the old style round all cop per FJW Generator frame which provides the customer with the original Classic pipe welding arc Engine Idler The Pipeliner amp 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 main tained within 10 at all loads u
97. WIDTH DEPTH WEIGHT 45 500 in 24 00 in 68 00 in 1302 16 1156 mm 610 mm 1727 mm 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 2000 KUBOTA LINCOLN B Return to Section Return to Master TOC Return to Section TOC ojo o E 5 5 R7 9 1 0 gt 813 Return to Section TOC Return to Master TOC Return to Master TOC Bes INSTALLATION 9 GENERAL DESCRIPTION The Pipeliner amp 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 amp 200D will provide constant volt age output for running the LN 25 wire feeder The optional Remote Control Kit provides a remote control rheostat for remote fine current and open circuit voltage adjustment The Pipeliner amp 200D KUBOTA has Diesel Engine Protection In the event of sudden low oil pressure or high coolant temperature the engine immediately shuts down The Pipeliner amp 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 auxi
98. abi cendres RE ius Fo dos 13 DC Excitet Test usce rede 13 Idl r Solenoid Test nedare Pad 17 Main Generator b eee ee yee 19 Flashing The EleldS segis edie needs RE Par 23 Engine Alternator Test onc ede eee eyes ae ee ee TEE EA 27 Pressure Temp Switch F 29 Current Sensor kao a bb RR ga 4 F 33 Engine Throttle Adjustment Test Perkins Only F 37 Wavelorimns pede eae ae s en dg ed E Be F 41 43 Removal amp Replacement Procedures F 45 DC Armature amp Field CoilS e TR ERES d F 45 Generator 2 pes P eee ned 49 Generator Armature 2 2 2 61 Hetest and ier Peds weeds pes De 45 496 9 eRe bed 63 PIPEL
99. able for adjusting the OCV at the welding site For Codes 10910 and above 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 Wire Feed Module K623 1 Provides constant volt age 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 con tactor 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 LN 23P to any Lincoln power source Makes 14 pin con nection at power source Magnum 250 Innershield Gun for LN 23P K355 10 For lighter weight and easier handling Rated 250 amps 6096 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 amp Internal Contactor Requires Wire Feed Module Remote Voltage Control Kit for LN 25 K444 2 Provides 25
100. acity 9 9 Qty 9 4 liter Consult the engine owners manual for the proper frequency and procedure ENGINE MAINTENANCE Refer to the Engine s operation and maintenance man ual for additional information on the engine PIPELINER 200G LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC ojo o Fie 5 5 8 R7 9 1 0 gt 813 oO oO Return to Section TOC Return to Master TOC Return to Master TOC 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 con stantly or in excessively dirty locations it may be nec essary 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 greasing 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 rotat ing armature when stoning the commutator The generator brushes are properly adjusted wh
101. ade of fuel recommended in the Engine Operator s Manual Make sure fuel valve on the sediment bowl 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 alter nate antifreeze recommendations INSTALLATION AAA 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 work ing 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 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 batter
102. al division represents 2 milliseconds in time Note Scope probes connected at machine 115VDC receptacle O10 5 10 9 1 0 lz 813 pir oO oO ayo SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC eit Internal Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B p TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AND SELECTOR SWITCH AT MAXIMUM Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 50 volts 5ms 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 O10 5 10 9 1 0 lz 813 pir oO oO SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC iine Internal Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B TROUBLESHOOTING 8 REPAIR inis TYPICAL DC WELD VOLTAGE WAVEFORM MACHINE LOADED SELECTOR SWITCH AT MAXIM
103. al 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 stan dard mufflers included with these welders do not qual ify as spark arresters When required by local regula tions suitable spark arrester must be installed and properly maintained CAUTION Use of incorrect arrester may lead to engine dam age or performance loss Contact the engine manu facturer for specific recommendations 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 unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an out side area INSTALLATION AA 3 CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES 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 o
104. ame must be securely connected to the metal frame of the vehicle When this engine driven welder is con nected 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 sec tion 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 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 5 9 1 0 gt 813 oO oO Return to Section Return to Master TOC Return to Master TOC 4 To achieve optimum engine performance the Pipeliner amp 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 mani
105. associated wires for loose or faulty connections See the Wiring Diagram Check the current range selector switch and contacts for proper operation Perform the Main Generator Shunt Field Winding Test The main armature may be faulty Check for grounds The actual welding current is 1 Check the main DC generator 1 The engine operating speed much greater than is indicated brushes for good commutation may be too high If necessar on the dials and alignment Contact the perform the Engine Throttle Lincoln Electric Service Dept 1 888 935 3877 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 not understand the test procedures 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 LINCOLN B 24 TROUBLESHOOTING 8 REPAIR dii Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The engine will not return to low 1 Make sure the idler control 1 Check the idler control switch idle when the welding and switch is set to the Auto and associated leads for auxiliary loads are removed posit
106. be Air filter element Check and adjust idle speed Perkins 080109080 Donaldson 181050 Nelson 70206N Tighten cylinder head Valve clearances Electrical systems Intake 008 exhaust 008 nuts and bolts for tightness Injector performance Leaks or engine damage Battery C Clean Inspect Notes Replace Contact Perkins 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 525557 PIPELINER 2000 PERKINS LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo o Fle 5 8 R7 9 1 0 gt 2 oO oO Return to Section Return to Master TOC DD 5 MAINTENANCE 1 Case Front Assembly 2 Engine Assembly 3 Exciter Frame Armature Assembly 4 Generator Frame Armature amp Coupling 5 Fuel Tank Assembly 6 Generator amp Exciter Brush Holder Assemblies 7 Base amp Lift Bale Assembly 8 Idler Solenoid Assembly 9 Radiator Assembly 10 Roof amp Doors Figure DD 2 Major Component Location
107. ble to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the main arma ture MATERIALS NEEDED Rope sling 5 8 Wrench Wood or steel blocks PIPELINER 200 LINCOLN F 61 TROUBLESHOOTING amp REPAIR po MAIN GENERATOR ARMATURE REMOVAL AND REPLACEMENT PROCEDURE FIGURE F 28 MAIN GENERATOR ARMATURE MOUNTING o ke 9 2 5 Return to Master S BLOWER PADDLE lt gt 818 21022 GA 5 2 2 2 2 3 3 5 2 MOUNTING BOLTS 2 LOCK WASHERS 8 5 a OFA 2 2 PROCEDURE 1 Turn the engine OFF Replacement Refer to Figure F 28 2 Perform DC Exciter Armature Removal 1 Support the armature with the rope sling procedure Mount the armature to the engine rotating it 3 Perf te m 1 8 turn in either direction to achieve attach ment Before removing the sling be 8 e Removal procedure careful to support the armature with the wood mit 4 Using the rope sling support the armature or steel blocks under the engine With the 0159 5 8 wrench install the eight bolts and lock 5 8 5 Make sure the engine supported with the washers that attach the
108. c et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier iv SAFETY iv 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent
109. c or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated b EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts c Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 e In some c it m nec ry to remov fet n MM 2 necassary Sale minimize exposure to fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Ne
110. c when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 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 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 ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel 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 applicat
111. 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 ground ing type receptacle for auxiliary power Welding Generator The Pipeliner 200D uses the old style round all cop per 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 ar
112. d 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 rotat ing 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 pig tail 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 commu tator as the armature rotates at full speed until contact is made across the full face of the brushes After ston ing blow out the dust with low pressure air Arcing or excessive exciter brush wear indicates a pos
113. d hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http Awww lincolnelectric com safety for additional safety information Jan 09 PIPELINER 200 LINCOLN B Return to Master Return to Master TOC o 2 0 lt 5 Return to Master PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter touj
114. detains qe WR 6 Return to Master o He 9 5 Return to Master PIPELINER 2000 KUBOTA LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 5 Return to Section TOC Return to Master TOC Q p 8 5 INSTALLATION A TECHNICAL SPECIFICATIONS PIPELINER amp 200D KUBOTA K6090 11 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities System 4 Oylinder 4 Cycle 134 1 cu in 12VDC battery Fuel 15 gal Naturally Aspirated 2 2 Itrs Group 45 650 57L Kubota Water Cooled High Idle 1600 cold crank amps V2203M Diesel Engine Low Idle 1400 Bore x Stroke 1 4 KW Starter Oil 8 0 Qts Cast Iron Cylinder Full Load 1600 40 A Alternator 7 61 Block Crankcase 3 43 x 3 64 w built in reg 9 5 27 8HP 91600 RPM 9 0L RATED OUTPUT 104 F 40 C WELDER DESCRIPTION RATED DC OUTPUT Duty DC CURRENT RANGE VOLTS RATED AMPS CYCLE Fine Adjustments in each Range 200 Amp DC Welder LINCOLN PLUS RATING 40V 200A All Copper Windings NEMA RATING 28V 200A 60 40 300 Amps Pure DC Power Generator RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power 1 75 kW 15 Amps 9 120V DC Q 35 Duty Cycle PHYSICAL DIMENSIONS HEIGHT
115. e 5 5 8 R7 9 1 0 gt 813 oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 5 10 9 1 0 lz 813 pir oO oO Return to Section TOC Return to Master TOC ret TROUBLESHOOTING amp REPAIR pel MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 17 TOP AND DOORS ASSEMBLY DETAILS BOLT NUT 4 1 DOOR 4 4 Using 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 LINCOLN pus TROUBLESHOOTING amp REPAIR diis MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 18 FUEL TANK MOUNTING DETAILS Return to Section TOC Return to Master TOC BOLTS NUTS WASHERS 4 FUEL LINE FUEL BOWL FUEL TANK Return to Section TOC Return to Master TOC 5 Perform the DC Exciter Armature Removal 7 Using the 9 16 wrench remove the four nuts bolts and washers holding the fuel tank 6 Turn off the fuel supply at the fuel bowl and assembly tothe rals remove the fuel line Plug the line to av
116. e faulty Check for grounds Check for loose or faulty connections or wires at the 120 VDC receptacle and associated circuitry See the Wiring Diagram CAUTION If for any reason you not understand the test procedures 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 LINCOLN Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC olo o ci 9 1 lz 813 515 4515 oO oO ayo Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The actual welding current is 1 Check the welding cables for 1 The engine RPM may be low much less than is indicated on loose or faulty connections If necessary perform the the dials Engine Throttle Adjustment 2 The welding cables may be Test PERKINS code 10929 excessively long or coiled 3 Check the main DC generator Perform the DC Exciter Test brushes for good commutation and alignment Contact the Check the fine current control field rheostat for resistance Lincoln Electric Service Dept 1 and proper operation Normal 888 935 3877 resistance is 64 ohms Check
117. e Lincoln plus output rating at 6096 duty cycle is 200 amperes at 40 Volts PIPELINER 200G LINCOLN Return to Section Return to Master TOC Return to Section TOC ojo o Fie 5 5 R7 9 1 0 gt 813 oO oO Return to Section Return to Master TOC Return to Master TOC BBB 4 CONTROL OF WELDING CURRENT CAUTION WHILE WELDING because current may arc between the contacts and damage the switch The Current Range Selector provides five overlap ping 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 pre ferred 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
118. e labeled and PIPELINER 200D PERKINS LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section TOC Return to Master TOC o ke 2 8 5 3 Cranking System A 12V electric starter is standard 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 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 2000 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 4 Press the Start button When the engine starts run ning 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 with in 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 dur ing cranking or after start up the IGNITION switch must be turned OFF
119. e test will also determine what component s may be faulty MATERIALS NEEDED 3 8 wrench Volt Ohmmeter Multimeter Wiring Diagram PIPELINER 200 LINCOLN F 13 TROUBLESHOOTING 8 REPAIR DC EXCITER TEST CONTINUED FIGURE F 1 120VDC RECEPTACLE Return to Section TOC Return to Master TOC SERIES COIL CONNECTION POINT NEGATIVE POSITIVE m 5 2 5 Return to Master TEST PROCEDURE 1 Turn off the engine and remove all external loads 2 Start the engine and put the idler switch in the HIGH olo e e o to the welder terminals and auxiliary receptacle idle position sls 3 Using the volt ohmmeter carefully check the DC 510 voltage at the 120V receptacle Observe proper 910 gt WARNING polarity The large slot of the receptacle is negative 2 See Figure 1 Normal voltage is 125 135VDC MOVING PARTS can injure no load with the engine at the high idle speed of 5 5 Remove guards only when necessary 1600 RPM If the voltage is normal the DC exciter c to perform service and replace them is functioning correctly If the voltage is low or not when the service requiring their present proceed to the next step removal is complete Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing e
120. e the 7 16 wrench to loosen the solenoid idle rod locking nut See Figures 13 amp 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 Return to Section TOC Return to Master TOC olo O10 5 10 9 1 0 lz 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo Fie 5 5 8 R7 9 1 0 gt 813 oO oO Return to Section Return to Master TOC p TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST CONTINUED PERKINS ONLY FIGURE F 14 SOLENOID LOCATION IDLER ADJUSTMENT BALL JOINT IDLER ROD PIPELINER 200 LINCOLN 8 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VDC SUPPLY HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 50 volts 2ms This is the typical auxiliary output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizont
121. eassembly the armature locking nut 212 1 l should be torqued to 170 105 Install 8 2 pac nut a remove the exciter new sleeve collar if necessary Part number ll 9 15 T5345 Bend the washer against the 3 Using 3 8 wrench remove the two brush locking nut 2 holder assemblies Note insulator placement 8 Install the brush holder assemblies Note eic for reassembly insulator placement 4 Bend the flat washer away from the armature 9 Check the armature air gap Minimum gap locking nut should be 025 5 Using the 1 5 8 socket wrench remove the 10 Install the exciter cover armature locking nut washer and sleeve col lar 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 Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC 2 8 5 47 TROUBLESHOOTING amp REPAIR DC EXCITER ARMATURE amp FIELD COILS REMOVAL AND REPLACEMENT PROCEDURE Field Coils Removal Procedure 1 Perform the DC Exciter Armature Removal 2 Using the 3 8 wrench remove the leads fr
122. ection Return to Master TOC Return to Master TOC 4 PRE OPERATION INSTALLATION A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK 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 QA vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off ys Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual 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 lead to engine age or performance loss Contact the engine manu facturer for specific recommendations
123. ed without automat ic 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 alterna tor 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 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 igni tion 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 PIPELINER 200G LINCOLN eee MAINTENANCE Return to Section Return to Master TOC ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE 50 HOURS EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 600 HOURS OR 12 MONTHS ENGINE SERVICE NOTE 2 MAINTENANCE ITEM TYPE OR QUANTITY Coolant level Concentration of antifreeze 50 50
124. el and add a 50 50 solution as needed see engine manual or antifreeze container for alter nate antifreeze recommendations PIPELINER 2000 KUBOTA LINCOLN B ind INSTALLATION Battery Charging A WARNING GASES FROM BATTERY can explode e Keep sparks and cigarettes away Return to Section TOC Return to Master TOC 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 nega tive cable from the old battery first and con nect the negative cable to the new battery last b Connecting a battery charger remove the bat tery from the welder by disconnecting the neg ative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base 2 Return to Section TOC Return to Master TOC To prevent ELECTRICAL DAMAGE when a Installing a new battery b Using a booster Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not run ning To prevent BATTERY BUCKLING tighten nuts on battery clamp until snug O10 5 10 9 1 0 lz 813 pir oO oO ayo The PIPELINER 200D
125. embly Engine Assembly Exciter Frame Armature Assembly Generator Frame Armature amp Coupling Fuel Tank Assembly Generator amp Exciter Brush Holder Assemblies Base amp Lift Bale Assembly Radiator Assembly Roof amp Doors Figure D 2 Major Component Location PIPELINER 2000 KUBOTA LINCOLN B D 5 0 6 5 PIPELINER 2000 KUBOTA LINCOLN EH D 6 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes OF CONTENTS INSTALLATION SECTION 58 o 5 installation 9222404604 ces one 1 9 2 Technical Specifications s sirasi eee ne Bae PERSE Ee eee PER E AA 2 RETRO T E CIT te dea sew hea ease ais AA 3 Trailers Polarity Control 8 Cable Sizes AA 4 Oil Fuel Cooling System amp Battery Charging 2 AA 5 Return to Master TOC o He 9 5 Return to Master PIPELINER 2000 PERKINS LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q
126. en 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 pig tail Acomplete 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 commu tator as the armature rotates at full speed until contact is made across the full face of the brushes After ston ing blow out the dust with low pressure air Arcing or excessive exciter brush wear indicates a pos sible misaligned shaft Have an authorized Field Service Shop check and realign the shaft MAINTENANCE DDD 3 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 ground ing of the battery and TBI controller 2 If desired the welder can be us
127. enerator 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 Using the 7 16 wrench tighten the main gen erator brush bracket clamping bolt Note the position of the drill spot Install the eight brushes against the main commutator Observe the positions you noted during disassembly Using the slot head screw driver install the brush bracket wrap around cover with two nuts and screws 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 Reconnect all leads previously removed See the Wiring Diagram 8 9 Perform the DC Exciter Reassembly Procedure Carefully position the fuel tank to the mount ing 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 10 Carefully set the top and doors assembly 11 into place Install the L shaped door hooks Using the 1 2 wrench install the four nuts and bolts holding the case top and
128. ent 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 rough ness of surface on which the trailer will be operat ed 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 e 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 compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacture s 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 mount ing rail See size recommendations below For pos itive polarity connect the electrode cable to the termi nal marked For Negative polarity connect the electrode cable to the stud These connections should be checked periodically and
129. es 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 Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from 1 Batterymarch Park PO box 9101 Quincy 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place an
130. fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease COMMUTATOR AND BRUSHES A 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 rotat ing 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 2000 KUBOTA LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC z 2 cfc 515 pie oO ayo Return to Section TOC Return to Master TOC Return to Master TOC 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 experi enced maintenance man
131. fold to be angled down and 50 degrees for the welder con trol 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 LIFT BAIL A lift bail is provided for lifting with a hoist WARNING Lift only with equipment of adequate lifting capacity sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trail er 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 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 dam age 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
132. 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 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 126 1 2 K264 8 and K355 10 PIPELINER 2000 KUBOTA LINCOLN B Return to Master Return to Master TOC o He 9 5 Return to Master D 1 2 TABLE OF CONTENTS MAINTENANCE SECTION Maintenance Ed Re da 0 1 Safety Precautions Bearings Commutator 8 Brushes D 2 Idler Maintenances EE RR Rx ERG qe ERN ES a Rd D 3 Engine ServiGe ERE amia bipes SE Fevrier NX LES P ds D 4 Major Component Location 4 D 5 PIPELINER 2000 KUBOTA LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 5 10 9 1 0 gt 813 pir oO oO
133. gure F 7 O10 5 9 1 0 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN 8 ojo o Fir 5 5 8 R7 9 1 0 gt 813 Return to Section TOC Return to Master TOC F 25 TROUBLESHOOTING amp REPAIR res 9 o E FLASHING THE FIELDS continued 9 8 FIGURE 8 BRUSH HOLDER BATTERY JUMPER CONNECTIONS 2 5 2 2 WARRANTY 3 2 Iw a P ail 8 2 5 RAISE o m 9 3 EN 019 gil BRUSH OFF eje NE lt 3 7 COMMUTATOR 513 oje BATTERY lt TO POSITIVE TERMINAL gt TERMINAL 3 Raise one exciter brush off the armature commuta 6 tor 4 Using the jumper leads and the 12VDC battery first 7 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 Remove both leads from the brush holders and the battery Install the brush removed in step 3 8 Install the exciter cover u
134. h the shunt windings thus controlling the amount of magnet ism created in the field windings Open circuit weld voltage can also be controlled by the field rheostat con trol PIPELINER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo Fie 5 5 8 R7 9 1 0 gt 813 515 oO oO r t Return to Section TOC Return to Master TOC E 7 THEORY OF OPERATION FIGURE E 7 DC GENERATOR THEORY zmaizco SHUNT FIELD WINDINGS DC CURRENT D GENERATOR MECHANICAL COUPLING ARMATURE ARMATURE SHAFT DC CURRENTE SHUNT FIELD WINDINGS 4Z2mDDCO 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 con nected 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 al
135. he welder be sure you use ample size welding cables RECOMMENDED COPPER CABLE SIZES Cable Sizes for Combined Length of Electrode Plus Work Cable Up to 200 ft 200 250 ft Duty Cycle 60 1 0 PIPELINER 200G LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section TOC Return to Master TOC o 2 0 8 5 5 PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instruc tions supplied with this machine 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 po not overfill tank fuel expan sion may cause overflow GASOLINE FUEL ONLY OIL 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 if required DO NOT OVERFILL FUEL Fill the fuel tank with the gr
136. he 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 PIPELINER 200 LINCOLN B in TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The engine starts and runs at 1 Check for loose or missing Check for loose or broken correct speed but there is no or brushes in the DC exciter wires between the exciter very low welder output voltage brushes and the DC There is no DC auxiliary output The exciter may need receptacle and the fine flashing See Flashing the current control field rheostat voltage j Fields in this section See the Wiring Diagram Perform the DC Exciter Test Return to Section TOC Return to Master TOC The engine starts and runs at Check the welding cables for Check the fine current control the correct speed but there is loose or faulty connections field rheostat for resistance or very low welder output The and proper operation Normal resista
137. hile 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 Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the ar
138. ime 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 AUXILIARY POWER 1 75 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 volt age i e Cooper Bussmann Inc Model LP CC 15 or Littlefuse Model CCMR 15 PIPELINER 2000 WITH KUBOTA V2203M DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA Low idle 1400 RPM 32gal hr 1 21Itrs r No Load High idle 1600 Rpm No load 37gal hr 1 40ltrs hr 200 Amps 28 Volts 85gal hr 3 22ltrs hr Auxiliary Power 1 750 Watts 5Ogal hr 1 89ltrs hr PIPELINER 2000 KUBOTA LINCOLN B 91 TABLE OF CONTENTS ACCESSORIES SECTION c PACCOSS ONES E a aae E 1 Optional Features 2 2 Return to Master Return to Master TOC o He 9 5 Return to Master PIPELINER 2000 KUBOTA LINCOLN B
139. in 10 at all loads up to rated capacity When welding available auxiliary power will be reduced PIPELINER 200G LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC ojo O o Fie 5 5 9 1 0 o gt 813 oO oO r t Return to Section TOC Return to Master TOC Return to Master TOC AAA 3 SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK kill not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 23 Use in open well ventilated areas or GA vent exhaust outside MOVING PARTS can injure not operate with doors open or guards off ys Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual 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 stan dard mufflers included
140. ine 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 13 14 RED LEAD 2 120 VOLTS EXCITER SERIES FIELD DC 1 T AWWA 12 T14 EXCITER SHUNT FIELD 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 resis tances vary significantly REPLACEMENT MAY BE NECESSARY If the shunt and series coils are good and the exciter is not operating properly the exciter arma ture may be faulty Replace the exciter armature After the test and repairs are completed install the exciter cover using the 3 8 nut driver PIPELINER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 5 10 9 1 0 oO oO Return to Section Return to Master TOC
141. ing to operate with long arc tech niques 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 2000 KUBOTA LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section TOC Return to Master TOC ke 2 8 5 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 2 In the Auto w position the oper ates as follows a When welding or drawing power for lights or tools approximately 100 watts minimum from the recep tacles 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 t
142. inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when neces sary 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 kill not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work ground Always wear dry insulating gloves ENGINE EXHAUST kill 4 Use in open well ventilated areas vent exhaust outside 4 MOVING PARTS can injure 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 operator s 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 cur rent control through its entire range frequently Good practice is to turn the handle from maximum to minimum setting t
143. ion loose or faulty connections See the Wiring Diagram Return to Section TOC Return to Master TOC Make sure both welding and auxiliary loads are removed Check the CURRENT SENSING PC BOARD Check for mechanical Perform the Current Sense restrictions in the idler and Board Test Replace if throttle linkage PERKINS necessary code 10929 ONLY There may be a problem with the ECU 3 Perform the Throttle Body Controller or associated engine control ONLY components on Kubota Diesel 1114 11316 and GM Gas 10660 10913 11136 Contact the Lincoln Electric Service Dept 1 888 935 3877 Check for loose or faulty connections at the idler PC board PERKINS ECU in Kubota and Throttle Body Controller GM 3 0 liter The idler PC board Return to Section TOC Return to Master TOC PERKINS ECU in Kubota or Throttle Body Controller GM 3 0 liter may be faulty Contact the Lincoln Electric Service Dept 1 888 935 3877 olo o Fle equ 9 1 gt 2 cfc 515 pie oO oO CAUTION If for any reason you not understand the test procedures 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 LINCOLN Return to Section TOC Return to Master TOC TROUBLESHOOTING 8 REPAIR iis Observe Safety Guidelines detailed i
144. ion involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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 prod ucts 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 Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Jan 09 PIPELINER 200 LINCOLN B Return to Master TOC Return to Master TOC o Hr 2 0 lt 5 Return to Master SAFETY gt Z WELDING and CUTTING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area lf 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 hyd
145. lear 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 FIGURE D 1 2 Turn the engine by pressing the start button until the engine runs smoothly this should take approx imately 10 seconds 3 Fully close the air bleeding valve by turning it clock wise Contact your Kubota Engine repair facility if problems persist PIPELINER 2000 KUBOTA LINCOLN B MAINTENANCE 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 300 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 Return to Section TOC Return to Master TOC Electrical systems All nuts and bolts for tightness Leaks or engine damage Battery MAINTENANCE ITEM TYPE OR QUANTITY I Coolant level 11 Concentration of antifreeze 50 50 Water Ethylene Glycol Coolnt NOTE 3 9 5 qrts 9 0L olo I Engine oil level NOTE 1 e o Engine oil NOTE 1 amp 3 8 0 qrts 7 6L including filter
146. lector contacts should not be greased To keep the contacts clean rotate the cur rent control through its entire range frequently Good practice is to turn the handle from maximum to min imum 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 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 manufacturer s manual COOLING SYSTEM The PIPELINER 2000 KUBOTA is equipped with a pressure radiator Keep the radiator cap tight to pre vent loss of coolant Clean and flush the cooling sys tem 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 con stantly or in excessively dirty locations it may be nec essary 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 Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the
147. liary power This unit uses the Kubota V2203M Industrial water cooled diesel engine DESIGN FEATURES 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 ground ing type receptacle for auxiliary power an engine tem perature gauge a battery charging ammeter an oil pressure gauge and a high idle RPM adjustment knob WELDING GENERATOR The Pipeliner amp 200D KUBOTA 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 amp 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 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 main tained within x 1096 at all
148. low the engine to run at high idle speed for sever al 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 OPERATION BBB 3 STOPPING THE ENGINE Turn the Ignition switch to OFF At the end of each day s welding refill the fuel tank to minimize moisture condensation in the tank Also run ning 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 Refer to engine Operation and Maintenance manual for additional information on the engine supplied with this welder WELDER OPERATION WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp 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 7 5 Wear eye ear and body protection NM DUTY CYCLE The NEMA output rating of the Pipeliner amp 200G is 200 amperes at 280 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 Th
149. ment 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 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 trou bleshooting 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 LINCOLN Ese TROUBLESHOOTING amp REPAIR run OIL PRESSURE TEMPERATURE SWITCH TEST CONTINUED FIGURE F 10 SWITCH Return to Section TOC Return to Master TOC TEMP SW SENDER 525162 SWITCH SENDER 1 2 14 NPT SPADETERMINAL 194 03 3 16 SPADE TERMINAL Return to Section TOC Return to Master TOC 17026 3 WK TERMINAL TO GROUND TO CASE 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 6 With the engine running the resistance from Pressure Switch Sender terminal G to case ground should be as fol 2 Remove the two leads from the switch lows 3 Using the ohmmeter check the resistance from O approximately TO ohms te
150. moving the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent 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 Contents to locate the appropriate diagram CAUTION If for 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 LINCOLN B F 2 Return to Section Return to Master TOC Return to Section TOC ojo o E 5 5 8 R7 9 1 0 gt 6 1 8 oO Return to Section TOC Return to Master TOC Return to Maste
151. n feet and having no insulated joints or to the metal framework of a building which has been effectively grounded 0 5 National Code lists a number of alternate means of grounding electrical equipment LIFT BAIL A lift bail is provided for lifting with a hoist A WARNING Lift only with equipment of adequate lifting capacity sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bale is EQUIP MENT can damaged Do not operate machine while suspended from lift bale PIPELINER 2000 KUBOTA LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 5 10 9 1 0 813 oO oO Return to Section TOC Return to Master TOC AS INSTALLATION zm TRAILER 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 dam age 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 equipm
152. n the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The engine will NOT go to high 1 Check welding cables for loose 1 Check the idler control switch speed when a load is applied to or faulty connections and associated leads for the welding output terminals loose or faulty connections The engine does go to high See the Wiring Diagram speed when a load is applied to the DC auxiliary power 2 Check the CURRENT receptacle When the engine is SENSING PC BOARD operating in the high RPM Perform the Current Sense condition both welding output Replace if and DC auxiliary are normal Return to Section Return to Master TOC Perform the dler Solenoid Test PERKINS 10929 Check for loose or faulty connections at the idler PC board PERKINS ECU in Kubota and Throttle Body Controller GM 3 0 liter Return to Section TOC Return to Master TOC 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 1 888 935 3877 olo o 9 1 lz 812 515 4515 oO oO CAUTION If for any reason you not understand the test procedures are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 8
153. nce is 64 ohms Check associated wires for loose or faulty connections See the Check for open circuit voltage Wiring Diagram Check for loose or missing brushes in the welding generator DC auxiliary output voltage is normal at weld studs check heavy current carrying leads for loose 2 Perform the or corroded connections Shunt Field Winding Test 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 Return to Section TOC Return to Master TOC 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 olo o 9 1 lz 813 515 4515 oO oO ayo The main armature may be faulty Check for grounds and or shorts A 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 LINCOLN B Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC olo o Fle equ 9 1 gt 2 cfc 515 pie oO oO Retu
154. ngine speed High idle speed should be 1800 RPM If Necessary perform the Engine Throttle Adjustment Test PERKINS ONLY 10929 The Current Range Selector Switch may be faulty Check for proper operation and contact Check the DC generator brushes for good commutation and alignment Contact the Lincoln Electric Service Dept at 1 888 935 3877 CAUTION If for any reason you not understand the test procedures 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 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo Fie 5 5 9 1 0 gt Sie oO Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed throughout this manual Kubota EUC Codes LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE CORRECTIVE MEASURE LONG 1 SHORT 1 RPM IS OVER 115 OF RATED RPM 2070 RPM ACTUATOR IS STUCK REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED LONG 1 SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND 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 LONG 1 S
155. ns out while the fuel pump is operating air may be entrapped in the fuel dis tribution system If this happens bleeding of the fuel system may be necessary Use qualified personnel to do this per the instructions in the MAINTENANCE tion of this manual ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial 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 2000 KUBOTA LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 5 10 9 1 0 gt 813 oO oO Return to Section Return to Master TOC B3 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 suc cessful engine break in most diesel powered equip ment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moder ate to heavy loading of the engine may sometimes be necessary Caution must be
156. oid 8 Carefully remove the fuel tank and set it aside spillage in a safe area O10 5 10 9 1 0 lz 813 pir oO oO Return to Section Return to Master TOC PIPELINER 200 LINCOLN 8 pud TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE olo CONTINUED 812 FIGURE F 19 SELECTOR SWITCH LEAD REMOVAL 9 5 7 513 SELECTOR SWITCH TERMINAL LEAD 5 gt EA SO 22 E 7 7 J 4 A OD KY Return to Section TOC Return to Master TOC 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 FIGURE F 20 OUTPUT TERMINAL LEAD REMOVAL ojo o Fie 5 5 8 R7 9 1 0 gt 813 oO oO POSITIVE OUTPUT TERMINAL AND LEAD GCE NN f 8S NY Cy Sx 20 Return to Section TOC Z5 0 8 10 Using the 3 4 wrench remove copper 11 Using the 3 4 wrench remove the heavy 3 strap from the negative output terminal See lead from the positive output terminal See o Figure F 20 Figure F 20 PIPELINER 200 LINCOLN TROUBLESHOOTING amp REPAIR po MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE 21 CHOKE CONTROL CABLE REMOVAL
157. oil and series coil resistance tests Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC ojo o Fie 5 5 8 R7 9 1 0 gt 813 oO oO Return to Section TOC Return to Master TOC Return to Master TOC F 16 TROUBLESHOOTING amp REPAIR F 16 DC EXCITER TEST continued FIGURE F 3 BRUSH HOLDER LEADS O WHITE FLEX LEAD 2 SMALL FLEX LEAD SOLID LEAD SHUNT COIL AND SERIES COIL RESISTANCE TESTS 7 Turn the engine OFF 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 small er flex lead shunt coil 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 11 positive and negative brush holder and also the bolted connection within the exciter bracket that connects T12 to the RED lead 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 f
158. om the brush holder Note lead placement for reassembly Using the 1 2 wrench remove the four bolts 8 9 two on each side holding the pole pieces to the exciter frame See Figure 15 10 Label and remove the tape and splices from the black and red leads that go to the idler board and 115VDC receptacle the Wiring Diagram Carefully slide the coils and pole pieces from the exciter frame Remove the coils from the pole pieces Reassembly 7 Assemble the new coils to their respective pole pieces Assemble the coil and pole pieces to the exciter frame with four bolts Make the necessary lead connections to the idler board and 115VDC receptacle Wrap the slices with tape Assemble the armature and brushes See the DC Exciter Armature Removal PIPELINER 200 LINCOLN 48 5 PIPELINER 200 LINCOLN amp F 48 901 J91Se N 901 J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL DOL uonoes DOL TROUBLESHOOTING 8 REPAIR p 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
159. onds of no load the engine con trol protection circuitry returns the engine to low idle RPM PIPELINER 200 LINCOLN B FIGURE 5 ENGINE CONTROL Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ENGINE ENGINE ZENITH THROTTLE FUEL BODY INJECTORS RPM CONTROLLER CONTROL WATER amp PRESSURE amp AIRTEMP MAP WATER TEMP SENSOR SENSOR SENSOR ENGINE IGNITION SWITCH GASOLINE ENGINE BATTERY STARTER ENGINE ALTERNATOR OIL amp TEMPERATURE SWITCH CIRCUITS FROM CURRENT SENSING P C BOARD COUPLED TO GENERATOR The 12VDC battery powers the starter motor and through the ignition switch the engine ignition circuitry gas models only the engine alternator the engine When the welding or auxiliary load is removed a preset time delay of about 15 seconds starts After approxi mately 15 seconds of no load the engine con trol protection circuitry returns the engine to low idle RPM control protection modules and associated circuits See the appropriate block diagram These engine con trol and protection modules monitor engine oil pres sure coolant temperature and engine RPM The sys tem shuts the engine down in the event of a sudden low oil pressure or high coolant temperature A warn ing light on the control panel provides fault codes or on some models the engine fault light will glo
160. opriate block diagram These engine con trol and protection modules monitor engine oil pres sure coolant temperature and engine RPM The sys tem shuts the engine down in the event of a sudden low oil pressure or high coolant temperature A warn ing light on the control panel provides fault codes or on some models the engine fault light will glow 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 con trol protection being used PIPELI GLOW PLUGS ENGINE CONTROL ENGINE HOUR SENSING BOARD ENGINE CONTROL UNIT ENGINE SPEED ACTUATOR KUBOTA COUPLED TO DIESEL GENERATOR ENGINE When the welding or auxiliary load is removed a preset time delay of about 15 seconds starts After approxi mately 15 seconds of no load the engine con trol protection circuitry returns the engine to low idle RPM NER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o Fie 5 5 810 9 1 0 gt 813 oO Return to Section TOC Return to
161. or loose or faulty connections at the idler PC board PERKINS ECU in Kubota and Throttle Body Controller GM 3 0 liter 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 1 888 935 3877 Check the ignition switch for proper operation Check the associated leads for loose or faulty connections See the Wiring Diagram Check the fuel solenoid Make sure it is opening when 12VDC is applied Except Kubota See the Wiring Diagram 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 CAUTION If for any reason you not understand the test procedures 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 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section TOC Return to Master TOC Q 2 0 8 5 10 TROUBLESHOOTING 8 REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISA
162. ours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l ar
163. p touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er 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 t
164. p 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 Ignition System A High Energy Distributor Type electronic ignition is standard PIPELINER 200G LINCOLN B Return to Section Return to Master TOC Return to Section TOC O10 5 10 9 1 0 gt 813 pir oO oO ayo Return to Section TOC Return to Master TOC Return to Master TOC BBB 3 Cranking System A 12V electric starter is standard 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 High Idle RPM Adjustment 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 fur ther adjustment of the OCV Total OCV adjustment range is about 10 Volts ENGINE OPERATION STARTING THE GM 3 0L ENGINE Turn the Idler control switch to HIGH Optional Turn the Ignition switch to ON Press the Start button If the engine fails to start in 20 seconds wait 30 sec onds before repeating the above procedure Al
165. quipment 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 Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B ras TROUBLESHOOTING amp REPAIR DC EXCITER TEST CONTINUED FIGURE 2 EXCITER COVER REMOVAL Return to Section TOC Return to Master TOC IW WARRANTY 5 lt gt CHECK VOLTAGE AT BRUSH HOLDERS HERE RIGHT SIDE IS Return to Master TOC Return to Section TOC 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 careful ly 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 185VDC 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 ojo o Fie 5 5 R7 9 1 0 gt 813 oO 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 c
166. r TOC E TROUBLESHOOTING amp 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 CAUTION Sometimes machine failures appear to be due to board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems 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 Ifthe problem persists replace the suspect 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 body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected ATTENTION to a grounded part of the Static Sensitive 2 frame Devices Handle only at Static Safe Workstations If you don t have wrist strap touch an un painted grounded part of the equipment frame Kee
167. r 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 sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bail is damaged not operate machine while suspended from lift bail FALLING EQUIPMENT can cause injury PIPELINER 2000 PERKINS LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC o O10 5 lz 813 pir oO r t Return to Section TOC Return to Master TOC Return to Master TOC
168. raulic lines Have a fire extinguisher readily available 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 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 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical Work cabl
169. rminal WK to case ground This is normal 40 PSI equals approximately 105 ohms ly closed switch and should be at a very low resistance Less than 1 ohm ojo o E 5 5 8 R7 9 1 0 gt 813 80 PSI equals approximately 187 ohms 4 Using the ohmmeter check the resistance from Ps Meplace the Wo praviotiely famgvad terminal G to case ground This resistance should be approximately 10 ohms with zero PSI oil pressure 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 Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 5 Return to Section Return to Master TOC 2 8 5 TROUBLESHOOTING amp REPAIR din OIL PRESSURE TEMPERATURE SWITCH TEST CONTINUED Temperature Switch Sender Resistance Test 525162 Kubota and Perkins Only PROCEDURE 1 With the engine not running and at room 6 temperature locate the Temperature Switch Sender 2 Remove the two leads from the switch 3 Using the ohmmeter check the resistance from terminal
170. rn to Master TOC F 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S The welding output varies abnormally The auxiliary output remains constant The engine is operating correctly 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 OUTPUT PROBLEMS Check for loose or faulty welding cables This may be a normal condition The machine will normally lose some output as the components are heated Check for loose worn dirty or poorly seated main DC generator brushes The main armature commutator may need cleaning Check the DC receptacle and plug for loose or faulty connections Check the 15 Amp fuse Not on GM 3 0L gas 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 Perform the Shunt Field Winding Test Check the current range selector switch and contacts for proper operation While the machine is loaded check the interpole and series coils for signs of arcing This condition would indicate shorted turns in the coil The main armature may b
171. rn to Section TOC Return to Master TOC Return to Master TOC BBB 2 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill not touch electrically live parts or electrode with skin or wet clothing e 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 40 MOVING PARTS injure not operate with doors open or guards off ys Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s 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 amp 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 amp 200G will provide con stant 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 RATED OUTPUT D
172. ructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas vent exhaust outside MOVING PARTS can injure not operate with doors open or guards off A gt Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual Operate the welder with the doors closed Leaving the doors open changes the designed air flow and can cause overheating STARTING THE PIPELINER 2000 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 IGNI TION 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 protec
173. ry voltage 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 BOLT NUT 4 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 volt age 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 cor rectly If the voltage does not drop to zero replace the current sensor PCB PIPELINER 200 LINCOLN B F 34 35 PIPELINER 200 LINCOLN 8 ELECTRIC TROUBLESHOOTING amp REPAIR CURRENT SENSOR PCB TEST CONTINUED FIGURE F 12 CURRENT SENSING PCB F 35 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL DOL uonoes 36 5 PIPELINER 200 LINCOLN amp F 36 901 J91Se N DOL J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL DOL uonoes DOL Return to Section Return to Master TOC Return to Section TOC
174. sing the 3 8 nut driver Start the engine The exciter should produce DC output voltage PIPELINER 200 LINCOLN 26 5 PIPELINER 200 LINCOLN amp F 26 901 01 901 J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL uonoes DOL uonoes DOL TROUBLESHOOTING amp REPAIR pet ENGINE ALTERNATOR TEST A 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 Section TOC Return to Master 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 trou bleshooting 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 Return to Section TOC Return to Master TOC O10 5 10 9 1 0 813 oO oO Return to Section
175. spark arrestor clamp and adapter for mounting to the muffler exhaust pipe Cil Drain Kit K1586 1 Includes ball valve hose and clamp PIPELINER 2000 PERKINS LINCOLN B 91 TABLE OF CONTENTS MAINTENANCE SECTION _ 207 o Hr 5 Maintenance 22222251 00 1 9 gt g Safety Precautions 00 2 Bearings Commutator amp Brushes Idler Control Maintenance DD 3 ENGINE Service dea on gene or sees DD 4 Major Component Location 1 1 DD 5 Return to Master TOC o He 9 5 Return to Master PIPELINER 2000 PERKINS LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC O10 5 9 1 0 gt 813 oO oO Return to Section TOC Return to Master TOC Return to Master TOC DD 2 SAFETY PRECAUTIONS WARNING 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 neces sary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near mo
176. t rating of the Pipeliner amp 200D is 200 amperes at 280 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 t The Lincoln Plus output rating at 6096 duty cycle is 200 amperes at 40 Volts CONTROL OF WELDING CURRENT CAUTION DO TURN THE RANGE SELEC TOR WHILE WELDING because the current may arc between the contacts and damage the switch The Current Range Selector provides five overlap ping 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 pre ferred 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 2000 PERKINS LINCOLN B BET OPERATION When forceful digging arc is required usually for vertical and overhead welding use a higher Current Range Selector setting
177. tal bed or frame of vehicle Follow vehicle manufacture s instructions INSTALLATION 4 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 mount ing 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 Cable Sizes for Combined Length of Electrode Plus Work Cable Duty Cycle Up to 200 ft 200 250 ft 60 1 1 0 PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instructions supplied with this machine A 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 DIESEL FUEL fumes to clear before starting can engine cause fire Do not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY PIPELINER 200D PERKINS LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q
178. te of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp 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 A Ah To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment ZW hot 1 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 3 0 ELECTRIC AND 59 FIELDS 1 Do not the fuel near an open weld dangerous ing ar
179. ternating AC voltage which must be recti fied In a conventional DC generator machine rectifi cation is provided mechanically by means of a commu tator Acommutator is a cylinder formed of copper seg ments 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 com mutator provides full wave rectification transforming the voltage waveform between brushes and making available a DC voltage to the external circuit PIPELINER 200 LINCOLN B guy E 7 8 5 PIPELINER 200 LINCOLN amp E 8 901 J91Se N DOL J91Se N 01 901 J91Se N 01 901 01 DOL uonoes DOL DOL uonoes DOL Return to Master Return to Master TOC o He 9 5 Return to Master F1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR F Troubleshooting and Repair F 1 How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting ERR 4 Test
180. tightened if neces sary When welding at a considerable distance from the welder be sure you use ample sized welding cables RECOMMENDED COPPER CABLE SIZES Cables Sizes for Combined Length of Electrode Plus Work Cable Duty Cycle 200 to 250ft Up to 200ft 61m PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instruc tions supplied with this machine 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 DIESEL FUEL fumes to clear before starting can engine cause fire not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY OIL 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 manufacturer s recommendations Upon receipt of the welder check the engine dipstick to be sure the is at the full mark DO NOT overfill FUEL Fill the fuel tank with the grade of fuel recommended the Engine Operator s 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 lev
181. time during the engine s early life However if the welder is subjected to extensive light loading occasional moder ate 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 OPERATION BB 4 WELDER OPERATION WARNING ELECTRIC SHOCK kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp GASES can be dangerous Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone 2 7 WELDING SPARKS can cause fire or WE explosion Keep flammable material away ARC RAYS can burn 22 Wear eye ear and body protection DUTY CYCLE The NEMA outpu
182. tion 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 at the factory and should require no adjusting when received COLD WEATHER STARTING 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 cold starting 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 day s 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 ru
183. ty notes and precautions detailed throughout this manual 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 trou bleshooting 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 LINCOLN F 19 TROUBLESHOOTING amp REPAIR pen MAIN GENERATOR SHUNT FIELD WINDING TEST continued FIGURE F 5 PLUG P10 LOCATION Return to Section TOC Return to Master TOC CL 9 PLUG P10 2 B EM TEST PROCEDURE Turn the engine OFF Return to Section TOC Return to Master TOC Unlatch lift and secure the right side door Locate plug P10 See Figure F 5 Remove plug 10 O10 5 9 1 0 lz 813 olo Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B TROUBLESHOOTING 8 REPAIR bel MAIN GENERATOR SHUNT FIELD WINDING TEST continued FIGURE F 6 PLUG P10 PIN ASSIGNMENTS PIN 3 Return to Section TOC Return to Master TOC PIN 5
184. ver coil the electrode lead around your body 14 Do not put your hands near the engine fan 2 d 3 Do not place your body between the electrode and Do not attempt to override the governor or work cables If the electrode cable is on your right idler by pushing on the throttle control rods side the work cable should also be on your right side M while the engine is running Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate PIPELINER 200 LINCOLN Return to Master o O 5 0 gt 2 tc Return to Master TOC Return to Master TOC SAFETY ELECTRIC SHOCK kill 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 w
185. ving 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 E not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 4 Use open well ventilated areas vent exhaust outside 4 MOVING PARTS can injure not operate with doors open or guards off Ww Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s 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 cur rent control through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before start ing to weld 3 Put a drop of oil on the Current Range Selector shaft at least once every month MAINTENANCE DD 2 4 When necessary remove the sediment bowl from beneath the gas tank and clean out any accumulat ed dirt and water
186. w ojo o Fie 5 5 8 R7 9 1 0 gt 813 oO oO The engine 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 con trol protection being used Return to Section TOC Return to Master TOC PIPELINER 200 LINCOLN B ES THEORY OF OPERATION E FIGURE E 6 GENERATOR amp EXCITER TO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo o Fie 5 5 8 R7 9 1 0 gt 813 Return to Section TOC Return to Master TOC ENGINE CONTROL PROTECTION SELECTOR SERIES MECHANICAL GENERATOR COUPLING ARMATURE ARMATURE SHAFT BRUSHES amp COMMUTATOR INTERPOLE COILS GENERATOR FIELD CONTROL 271 EXCITER 1 OUTPUT TERMINAL Current Sensing PC Board RESIDUAL MAGNETISM SHUNT SERIES FIELD ENGINE MAIN GENERATOR ARMATURE amp FRAME AND DC EXCITER EXCITATION FLASHING The main generator armature and the exciter armature are mechanically coupled to the engine
187. water glycol mixture Radiator for contamination or blockage Coolant NOTE 3 9 9qrts 9 4L Engine oil level NOTE 1 1 amp 3 4 5415 4 3L including filter Return to Section TOC Return to Master TOC Fiera 25183250020 DE Good Year TTAVOSSS Good Year TTAVT220 Tighten cylinder head Electrical systems and bolts for tightness Arfiergamercheckmayberegd Leaks or engine damage GROUP 45 Inspect Clean 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 These preventive maintenance periods apply to average conditions of operation 520919 3 If necessary use shorter periods UARA R R R PIT 111 NENNEN 21114 HIE O10 5 9 1 0 lz 813 oO oO Return to Section TOC Return to Master TOC PIPELINER 200G LINCOLN B Return to Section Return to Section TOC ojo o Fle 5 8
188. wice each morning before start ing to weld MAINTENANCE 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 rec ommendations in the engine operation manual 4 Inspect the air filter daily more often in dusty con ditions when necessary clean or replace The air fil ter should never be removed while the engine is running The air filter element part number is Donaldson 181050 or Nelson 70206 5 When necessary remove the sediment bowl from beneath the gas tank and clean out any accumulat ed 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 replace ment 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 amp 200G is equipped with a pressure radi ator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodical ly to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type Cap
189. with these welders do not qual ify as spark arresters When required by local regula tions suitable spark arrester must be installed and properly maintained CAUTION Use of an incorrect arrester may lead to engine dam age or performance loss Contact the engine manu facturer for specific recommendations INSTALLATION AAA 3 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 unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an out side area CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES 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 be double insulated When this welder is mounted on a truck or trailer its fr
190. y clamp until snug BATTERY CHARGING The Pipeliner amp 200G is equipped with a wet charged battery The charging current is automatically regulat ed 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 LINCOLN 6 5 PIPELINER 2006 LINCOLN 6 901 901 901 01 901 J91Se N DOL DOL uonoes DOL DOL Return to Master Return to Master TOC o He 9 5 Return to Master TABLE 5 OPERATION SECTION Operation PC 1 Safety Precautions amp Design Summary 1 BBB 2 Engine Welder Operation BBB 3 Control of Welding Current 1 4 PIPELINER 200G LINCOLN B Return to Section Return to Master TOC Return to Section TOC ojo O o E 5 5 R7 9 1 0 gt 813 Retu
191. ystem EG the engine was allowed to run out of fuel perform the following steps using qualified personnel PIPELINER 2000 PERKINS LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o Fle 5 5 9 1 2 oO oO Return to Section TOC Return to Master TOC DD 4 DD 4 MAINTENANCE 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 1 Loosen by two or three turns the vent screw Figure DD 1 on the fuel inlet connection 3 Contact your Perkins Engine repair facility if prob lems persist FIGURE DD 1 ENGINE SERVICE 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 18 MONTHS ENGINE SERVICE NOTE 2 MAINTENANCE ITEM Coolant level TYPE OR QUANTITY Concentration of antifreeze 50 50 Water Ethylene Glycol Coolant NOTE 3 Engine oil level NOTE 1 Engine oil NOTE 1 amp 3 9 5qrts 9 0L 8 7qrts 8 2L including filter Engine oil filter Perkins 140517000 Drain water separator amp fuel strainer Fuel filter canister Tension of alternator drive belt Perkins 26560017 Alternator drive belt wear Alternator drive belt Air filter earlier check may

Lincoln Electric 200 Welder User Manual

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