Lincoln Electric 11498 User Manual

Page 1

PIPELINER®200D KUBOTA

200D

RETURN TO MAIN MENU

Safety Depends on You

Lincoln arc welding equipment is designed and built with safety in mind. However, your overall saf et y c an be in cr eased by pro pe r inst al la tion . .. a nd th oug htful oper ati on on yo ur par t. DO NOT INSTALL ,

OPERATE OR REPAIR THIS EQU I P M E NT WIT H O U T READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.

An d, mos t important ly, think before you act and be careful.

IM965-B

March, 2010

For Machines with Code Number 11498, 11591, 11644

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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1.c. Do not add the f ue l near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact wit h hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

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1.e. I n some cases it may be neces sary t o remove safety

gu a r ds to per f orm req u ired m a i nte n a nce . R e move guards only when necessary and replace them when the ma i n tena n ce re q u irin g t hei r r emov a l is com p lete . Always use the greatest care when working near moving parts.

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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowin g thr ou gh an y con du ctor causes localiz ed Electric and Ma gnetic Fields (EMF). Welding current cr eates EMF field s around welding cab les a nd welding machines

2.b. E MF fields m ay inter fe re with s om e pacema ke rs , and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Nev er coil t he electrode lead aroun d your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

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SAFETY

ELECTRIC SH OCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-fr ee

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 mu s t be per f orme d under el ectr i call y hazar d ous con ditions (in damp locati ons or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electro de re el, welding head, nozzle or se mi automatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. N ever s imult aneou sly to uch el ectri cally “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and ga se s. 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

we l d ing with elect r odes which requi r e s p e cia l ve n tila t ion such a s stai n less or har d faci n g (se e in str u cti ons on co nta ine r or M S DS) or on lea d or cadmium plated steel and other meta ls or co atings 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 ventil at io n. In c on fi ned spaces or in s om e circumst a nces , outd o ors , a resp i rat o r may be req u ired . Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause i njury or de ath. Alway s use eno ug h ventilatio n, especially in confined areas, to insure breathing air is safe.

vapors

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the ma t e rial sa fety da ta shee t ( M SDS) an d f ollo w y o ur employer’s safety practices. MSDS forms are available from yo u r wel d ing di stri b utor o r fr o m the m anu f a ctu r e r.

5.f. Also see item 1.b.

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iii

SAFETY

iii

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m e mber th a t we l din g sp a r ks and hot materials from welding can easily go through small cracks an d op eni ngs to ad jac ent are as. Avo id w eld ing n ear hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1 ) and the opera ti ng in fo rmation for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Co n t aine r s an d Pip i ng Th at Ha ve He ld Ha zard o u s Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increas e t he possibility of th e wel ding current pass ing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

the w el di ng sparks f ro m starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. U s e on l y comp r esse d gas cy lind e r s containing the correct shielding gas for the pr o c ess us e d a nd prop e rly ope r atin g re g u lato r s des i gned for t h e gas an d

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. A lw ays ke ep cylinde rs in a n upright p osition securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. R ead and follo w th e in str uctio ns o n co mpr essed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in ac cordance with th e U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse . U n c ourt-circ uit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégr aissage, ne ttoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’ au tr e personnel travaillant à p ro xi mi té au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des goutte s de laitie r e n fusion sont émises de l ’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Page 6

TThhaannkk YYoouu

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

Page 7

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

General Description...............................................................................................A-2

Design Features ....................................................................................................A-2

Pre-Operation Installation......................................................................................A-3

Safety Precautions ..........................................................................................A-3

Exhaust Spark Arrester ...................................................................................A-3

Location/Ventilation.........................................................................................A-3

Machine Grounding.........................................................................................A-3

Lift Bail ............................................................................................................A-3

Trailers ............................................................................................................A-4

Polarity Control and Cable Sizes ....................................................................A-4

Pre-Operation Service ...........................................................................................A-4

Oil....................................................................................................................A-4

Fuel .................................................................................................................A-4

Cooling System ...............................................................................................A-4

Battery Charging .............................................................................................A-5

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Operation .........................................................................................................Section B

Engine Operation...................................................................................................B-1

Starting The Kubota V2403M Engine, Cold Weather Starting .......................B-1

High Altitude Operation ...................................................................................B-1

Stopping the engine ........................................................................................B-1

Break-In...........................................................................................................B-1

Welder Operation...................................................................................................B-2

Duty Cycle.......................................................................................................B-2

Control of Welding Current..............................................................................B-2

Idler Operation ................................................................................................B-3

Auxiliary Power ...............................................................................................B-3

Fuel Consumption Data ..................................................................................B-3

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Accessories.....................................................................................................Section C

Optional Features (Field Installed) ........................................................................C-1

Wire Feed Options.................................................................................................C-1

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Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

General Instructions ..............................................................................................D-1

Cooling System .....................................................................................................D-1

Bearings ................................................................................................................D-1

Commutator and Brushes .....................................................................................D-1

Idler Maintenance..................................................................................................D-2

Nameplates ...........................................................................................................D-2

Purging Air from Fuel System................................................................................D-2

Engine Service Chart ............................................................................................D-3

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Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

Welder Troubleshooting ........................................................................................E-2

Engine Troubleshooting Guide ................................................................E-3,E-4,E-5

Electronic Idler Troubleshooting Guide...........................................................E-6,E-7

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Diagrams ..........................................................................................................Section F

Wiring Diagram ...................................................................................F-1,F-2,F-3,F-4

Dimension Print......................................................................................................F-5

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Parts List.....................................................................................................P-504 Series

Page 8

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - PIPELINER® 200D KUBOTA

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

4 Cylinder 4 Cycle 148.53 cu. in

Naturally Aspirated (2.43 ltrs) (Group 45, 650 57 L

Kubota Water-Cooled High Idle 1600 cold crank amps)

V2403M Diesel Engine Low Idle 1400 Bore x Stroke

Tier 4 interim Cast Iron Cylinder, Full Load 1600 40 A. Alternator 9.5 L

Compliant Block/Crankcase 3.43” x 4.03” w/ built in reg. Coolant 9.5 Qts

27.8HP @1600 RPM

12VDC battery

1.4 KW

Starter Oil: 10.04 Qts.

RATED OUTPUT @ 104°F(40°C) - WELDER

DESCRIPTION RATED DC OUTPUT Duty DC CURRENT RANGE

VOLTS @ RATED AMPS CYCLE

Fine Adjustments in each Range

Fuel: 15 gal.

9.0 L

A-1

200 Amp DC Welder

All Copper Windings NEMA RATING 28V @ 200A 60% 40-300 Amps

Pure DC Power Generator

LINCOLN PLUS RATING

98V DC Max. OCV @ 1600RPM

40V @ 200A

RATED OUTPUT @ 104°F(40°C) - GENERATOR

Auxiliary Power

1.75 kW 15 Amps @ 120V DC @ 35% Duty Cycle

(1)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

(2)

45.50

(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 exhuast elbow. Case height is 40.9 in.(1039mm).

in. 24.00 in. 68.00 in. 1302 lbs.

PIPELINER® 200D KUBOTA

Page 9

A-2

INSTALLATION

GENERAL DESCRIPTION

The Pipeliner® 200D is a heavy duty engine driven DC arc welding power source capable of providing DC constant current output for stick welding and DC TIG welding. With the addition of the optional Wire Feed Module the Pipeliner® 200D will provide constant voltage output for running the LN-25 wire feeder.

A-2

ENGINE IDLER

The Pipeliner® 200D KUBOTA is equipped with an electronic automatic engine idler. It automatically increases and decreases engine speed when starting and stopping welding or using auxiliary power. A builtin time delay permits changing electrodes before the engine slows to its low idle speed. The “Idler” control switch on the panel locks the idler in the full speed position when desired.

The optional Remote Control Kit provides a remote control rheostat for remote fine current and open circuit voltage adjustment.

The Pipeliner® 200D KUBOTA has Diesel Engine Protection. In the event of sudden low oil pressure or high coolant temperature, the engine immediately shuts down.

The Pipeliner® 200D KUBOTA has a current range of 40-300 DC amps with output ratings as follows:

RATED OUTPUT DUTY CYCLE

200A @ 28V 200A @ 40V

The unit is also capable of providing 1.75 kw of 120V DC auxiliary power.

This unit uses the Kubota V2403M Industrial water cooled diesel engine.

60% 60%

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 grounding type receptacle for auxiliary power, an engine temperature gauge, a battery charging ammeter an oil pressure gauge and a high idle RPM adjustment knob.

WELDING GENERATOR

The Pipeliner® 200D KUBOTA uses the old style, round, all copper FJW Generator frame which provides the customer with the original “Classic” pipe welding arc.

AUXILIARY POWER

1.75 kw of nominal 120V DC. Output voltage is maintained within ± 10% at all loads up to rated capacity.

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 s huts the engine down in the event of sudden low oil pressure or high coolant temperature. A warning light on the control panel will indicate such a fault. To reset the engine for restarting, turn the ignition switch off then on. Refer to Troubleshooting section for all warning light fault codes.

CUSTOM ARC™ HIGH IDLE RPM (OCV ) ADJUSTMENT - A Potentiometer is mounted on the

Control Panel that allows the operator to adjust the high idle engin e speed between 1450 and 1600 RPM’S. This is to allow further adjustment of the OCV. Total OCV adjustment range is about 15 volts.

OIL DRAIN VALVE- A ball valve, hose and clamp are standard.

REMOTE CONTROL- The Remote/Local switch and Receptacle are standard.

PIPELINER® 200D KUBOTA

Page 10

A-3

INSTALLATION

A-3

PRE-OPERATION INSTALLATION

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 can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at the

front of this 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 may lead to engine damage or performance loss. Contact the engine manufacturer 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 unrestricted flow of clean, cool air. Also, locate the welder so that engine exhaust fumes are properly vented to an

outside area.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, the surface shall b e covered w i t h a st ee l plate a t l e a s t .06”(1.6mm) thick, which shall extend not more than

5.90”(150mm) beyond the equipment on all side.

------------------------------------------------------------------------

MACHINE GROUNDING

According to the United States National Electrical Code, the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle.

Some state, local, or other codes or unusual operating circumstances may require the machine frame to be grounded. It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly. A machine grounding stud marked with the symbol is provided on the welding generator frame foot. In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which ha s been effectively gro unded. The U.S. National Code lists a number of alternate means of grounding electrical equipment.

LIFT BAIL

A lift bail is provided for lifting with a hoist.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------------

PIPELINER® 200D KUBOTA

Page 11

A-4

INSTALLATION

A-4

TRAILER (See Optional Features)

If the user adapts a non-Lincoln trailer, the user must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework.

3. Proper placement of the equipment on the trailer to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

4. Typical conditions of use, i.e., travel speed, roughness of surface on which the trailer will be operated; environmental conditions, likely maintenance.

5. Conformance with federal, state and local laws.

(1)

Consult your federal, state and local laws regarding specific

requirements for use on public highways.

VEHICLE MOUNTING

(1)

WARNING

Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.

• Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is stable under conditions of use.

• Do not exceed maximum rated loads for components such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehicle.

• Follow vehicle manufacture’s instructions.

------------------------------------------------------------------------

RECOMMENDED COPPER CABLE SIZES

Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.

200 60% 1 1/0

Cables Sizes for Combined Length of Electrode Plus Work Cable

(61 to 76m)

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.

• Ke ep sp arks a nd fl ame a w ay from tank.

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow

DIESEL FUEL

can

cause fire

DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur fuel in U.S.A. and Canada.

------------------------------------------------------------------------

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 oil is at the “full” mark. DO NOT overfill.

fumes to clear before starting engine.

• Do not overfill tank, fuel expansion may cause overflow.

POLARITY CONTROL AND CABLE SIZES

With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail. (See size recommendations below.) For positive polarity, connect the electrode cable to the terminal marked “+”. For Negative polarity, connect the electrode cable to the “-” stud. These connections should be checked periodically and tightened if necessary.

When welding at a considerable distance from the welder, be sure you use ample sized welding cables.

PIPELINER® 200D KUBOTA

FUEL

Fill the fuel tank with the grade of fuel recommended in 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 mixtu re of ethylene glycol antifreeze and wa ter. Check the radiator level and add a 50-50 solution as needed (see engine manual or antifreeze container for alternate antifreeze recommendations).

Page 12

A-5

INSTALLATION

Battery Charging

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away.

BATTERY ACID can burn eyes and skin.

• Wear gloves and eye protection and be careful when boosting, charging or working near battery.

To prevent EXPLOSION when:

a) Installing a new battery - disconnect the nega-

tive cable from the old battery first and connect the negative cable to the new battery last

b) Connecting a battery charger - remove the bat-

tery 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.

A-5

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 running.

• To prevent BATTERY BUCKLING, tighten nuts

on battery clamp until snug.

------------------------------------------------------------------------

The PIPELINER® 200D KUBOTA is equipped with a wet charged battery. The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.

When replacing, jumping or otherwise connecting the battery to the battery cables, the proper polarity must be observed. This system is NEGATIVE GROUND.

PIPELINER® 200D KUBOTA

Page 13

B-1

ENGINE OPERATION

OPERATION

COLD WEATHER STARTING:

B-1

WARNING

-------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

-------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

--------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at the

front of this operator’s manual.

Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating.

With a fully charged battery and the proper weight oil, the engine should start satisfactorily even down to about -5°F (-20°C), it maybe desirable to install coldstarting aides.

Note: Extreme cold weather staring may require longer glow plug operation.

WARNING

Under NO 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.

conditions should e t h e r or other

STARTING THE PIPELINER® 200D KUBOTA V2403M DIESEL ENGINE

1. Turn the “IDLER” switch to “HIGH”.

2. Turn the “IGNITION” switch to “ON”.

3. Press the Glow Plug button for 20 to 30 seconds. (maximum 60 seconds).

4. Press the Glow Plug button and the Start button at the same time. When the engine starts running, release both buttons. If the engine fails to start in 20 seconds, wait 30 seconds and repeat the above procedure.

5. Observe the oil pressure. If no pressure shows within 30 seconds, stop the engine and consult the engine operating manual. To stop the engine, turn the “IGNITION” switch to “OFF”.

6. If the engine protection warning light comes on during cranking or after start up, the “IGNITION” switch must be turned “OFF” to reset the engine protection system.

7. Allow the engine to run at high idle speed for several minutes to warm the engine. Stop the engine and recheck the oil level, after allowing sufficient time for the oil to drain into the pan. If the level is down, fill it to the full mark again. The engine controls were properly set at the factory and should require no adjusting when received.

When hauling the welder between job sites, close the valve on the water separator.

If the fuel supply is cut off or runs out while the fuel pump is operating, air may be entrapped in the fuel distribution system. If this happens, bleeding of the fuel system may be necessary. Use qualified personnel to do this per the instructions in the MAINTENANCE section of this manual.

ENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wetstacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal.

PIPELINER® 200D KUBOTA

Page 14

B-2

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 susce ptible to th e co nditions desc ribe d ab ove. To accomplish successful engine break-in, most dieselpowered equipment 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 moderate to heavy loading of the engine may sometimes be necessary. Caution must be observed in correctly loading a diesel/generator unit.

1. Connect the welder output studs to a suitable resistive load bank. Note that any attempt to short the output studs by connecting the welding leads together, direct shorting of the output studs, or connecting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty.

2. Set the welder controls for an output current and voltage within the welder rating and duty cycle. Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty.

3. Periodically shut off the engine and check the crankcase oil level.

OPERATION

WELDER OPERATION

WARNING

B-2

DUTY CYCLE

The NEMA output rating of the PIPELINER® 200D KUBOTA is 200 amperes at 28 arc volts on duty cycle (consult Specifications in this manual alternate ratings). Duty cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period.

CONTROL OF WELDING CURRENT

a 60%

for

CAUTION

DO NOT TURN THE “CURRENT RANGE SELECTOR” WHILE WELDING because the current may arc between the contacts and damage the switch.

------------------------------------------------------------------------

The “Current Range Selector” provides five overlapping current ranges. The “Fine Current Adjustment” adjusts the current from minimum to maximum within each range. Open circuit voltage is also controlled by the “Fine Current Adjustment” permitting control of the arc characteristics.

A high open circuit voltage setting provides the soft “buttering” arc with best resistance to pop-outs preferred for most welding. To get this characteristic, set the “Current Range Selector” to the lowest setting that still provides the current you need and set the “Fine Current Adjustment” near maximum. For example: to obtain 175 amps and a soft arc, set the “Current Range Selector” to the 190-120 position and then adjust the “Fine Current Adjustment” for 175 amps.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

FUMES & GASES can be dangerous.

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

------------------------------------------------------------------------

PIPELINER® 200D KUBOTA

When a forceful “digging” arc is required, usually for vertical and overhead welding, use a higher “Current Range Selector” setting and lower open circuit voltage. For example: to obtain 175 amps and a forceful arc, set the “Current Range Selector” to the 240-160 position and the “Fine Current Adjustment” setting to get 175 amps.

Some arc instability may be experienced with EXX10 electrodes when trying to operate with long arc techniques at settings at the lower end of the open circuit voltage range.

CAUTION

DO NOT attempt to set the “Current Range Selector” between the five points designated on the nameplate.

------------------------------------------------------------------------

These switches have a spring loaded cam which almost eliminates the possibility of setting this switch between the designated points.

Page 15

B-3

OPERATION

IDLER OPERATION

Start the engine with the “Idler” switch in the “High” position. Allow it to run at high idle speed for several minutes to warm the engine. See Specifications for operating speeds.

The idler is controlled by the “Idler” toggle switch on the welder control panel. The switch has two positions as follows:

1. In the “High” position, the engine control unit

increases the engine to high idle speed.

2. In the “Auto” / position, the idler oper-

ates as follows:

a. When welding or drawing power for lights or tools

(approximately 100 watts minimum) from the receptacles, the engine operates at high idle speed.

b. When welding ceases or the power load is turned

off, a preset time delay of about 15 seconds starts. This time delay cannot be adjusted.

B-3

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 kVA of 120 V DC auxiliary power is availiable at the receptacle located on the control panel.

When the High Speed Adjustment knob is in the MIN position, the voltage of the DC auxiliary output may be reduced to below the rating on the nameplate of the machine. It is recommended that the High Idle Speed Adjustment knob should be in the MAX position when using the DC auxiliary output.

Always replace blown fuse with type rated for DC voltage (i.e. Cooper Bussmann Inc. Model LP-CC-15 or Littlefuse Model CCMR-15.

PIPELINER® 200D WITH KUBOTA V2403M DIESEL ENGINE

TYPICAL FUEL CONSUMPTION DATA

Low idle (1400 RPM ) .39 gal/hr (1.46 ltrs/hr ) No Load

High idle ( 1600 Rpm ) .53 gal/hr (2.00 ltrs/hr ) No load

200 Amps @ 28 Volts .90 gal/hr (3.42 ltrs/hr )

Auxiliary Power 1,750 Watts .54 gal/hr (2.04 ltrs/hr)

PIPELINER® 200D KUBOTA

Page 16

C-1

ACCESSORIES

C-1

OPTIONAL FEATURES (Field Installed)

GENERAL OPTIONS

WARNING

Pipe Thawing with an arc welder can cause fire, explosion, damage to electric wiring or to the arc welder if done improperly. The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric.

------------------------------------------------------------------------

Spark Arrestor Kit (K903-1) - Includes a heavy gage steel, approved spark arrestor, clamp and adapter for mounting to the muffler exhaust pipe.

TRAILER (K953-1) - Two-wheeled trailer with optional fender and light package. For highway use, consult applicable federal, state, and local laws regarding possible additional requirements. There is a choice of 2 hitches, a fender & a light package.

K953-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-1 Fender & Light Kit K965-1 Cable Rack

WIRE FEED OPTIONS

Wire Feed Module (K623-1) - Provides constant

voltage (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25. (Factory installed on the K1643-6).

LN-15 Wire Feeder (K1870-1,-2)-Portable CC/CV unit for flux-cored and MIG welding.

LN-23P Wire Feeder (K316L-1)-Portable CV unit for Innershield pipe welding. Control cable operates contactor inside Wire Feed Module for “cold” electrode. Requires LN-23P Adapter Kit (K350-1) and Gun and Cable Assembly.

LN-23P Adapter Kit (K350-1)-Required to adapt LN23P to any Lincoln power source. Makes 14 pin connection at power source.

Magnum® 250 Innershield Gun (for LN-23P) (K355-10)-

For lighter weight and easier handling. Rated 250 amps, 60% duty cycle. For .068 through 5/64” (1.7 thr o ugh 2. 0 mm) Inners hield w ire an d inc l udes reduced speed switch. For pipewelding, an M11476 62° gun tube is recommended.

K1858-1 AIR CLEANER SERVICE INDICATOR

STICK OPTIONS

K704 ACCESSORY SET - Includes 35 ft.(10 m) of

electrode cable and 30 ft.(9 m) of work cable, headshield, work clamp and electrode holder. Cable is rated at 500 amps, 60% duty cycle.

Remote Control Kit (K924-5) - Contains remote control rheostat and 100 ft.(30.5 m) cable for adjusting the OCV at the welding site. (For Codes 10910 and above.)

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.

LN-25 Wire Feeder (K449)-Portable CC/CV unit for flux-cored and MIG welding. Includes Gas Solenoid & Internal Contactor. Requires Wire Feed Module.

Remote Voltage Control Kit for LN-25 (K444-2)

Provides 25 ft. (7.5m) of remote output voltage control and output jumper (2 and 4) for machines having 14 pin MS-type connector.

Magnum® 350 Innershield Gun (for LN-25)(K126-2)-

For self-shielded wire with 15 ft. (4.5m) cable. For .062-3/32” (1.6-2.8mm) wire.

Magnum® 200 MIG Gun (for LN-25)(K497-3)-With 15 ft. (4.5m) cable. For .025 (0.6m) wire.

Magnum Gun Connector KiT (K466-1) Connects Magnum 200 MIG gun to LN-25 Wire Feeder.

62° gun tube for Pipe Welding (KP1909-1)-

Recommended modification for K355-X or K345-X guns with 90° gun tubes. Compatible with K126-1,-2 K264-8 and K355-10.

PIPELINER® 200D KUBOTA

Page 17

D-1

MAINTENANCE

D-1

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 necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

Do not put your hands near the engine cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this 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 current control through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld.

3. Put a drop of oil on the “Current Range Selector”

shaft at least once every month.

PIPELINER® 200D KUBOTA

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® 200D KUBOTA is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the cooling system periodically to prevent clogging the passage and overheating the engine. When antifreeze is needed, always use the permanent type.

BEARINGS

This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal service. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one half ounce of grease per year. A pad of grease one inch wide, one inch long, and one inch high weighs approximately one half ounce. Overgreasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of the area. Wipe the fittings completely clean and use clean equipment. More bearing failures are caused by dirt introduced during greasing than from insufficient grease.

COMMUTATOR AND BRUSHES

WARNING

Uncovered rotating equipment can be dangerous. Use care so your hands, hair, clothing or tools do not catch in the rotating parts. Protect yourself from particles that may be thrown out by the rotating armature when stoning the commutator.

------------------------------------------------------------------------

Shifting of the commutator brushes may result in:

- Change in machine output

- Commutator damage

- Excessive brush wear

Periodically inspect the commutator, slip rings, and brushes by removing the covers. DO NOT remove or replace these covers while the machine is running. Commutators and slip rings require little attention. However, if they are black or appear uneven, have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Never use emery cloth or paper for this purpose.

Page 18

D-2

MAINTENANCE

D-2

Replace brushes when they wear within 1/4”(3.5mm) of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced maintenance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes. After stoning, blow out the dust with low pressure air.

Arcing or excessive exciter brush wear indicates a possible misaligned shaft. Have an authorized Field Service Shop check and realign the shaft.

IDLER MAINTENANCE

CAUTION

Before doing electrical work, disconnect the battery.

------------------------------------------------------------------------

When installing a new battery or using a jumper battery to start the engine, be sure the battery polarity is connected properly. The correct polarity is negative ground. Damage to the engine alternator and the Engine Control Unit can result from incorrect connection.

PU RG IN G AIR FRO M FU EL SYST EM (KUBOTA V2403M ENGINE)

WARNING

Keep fuel clear of open flames or arcs, allow engine to cool before working on the fuel system. Wipe up any spilled fuel and do not start engine until fumes clear.

------------------------------------------------------------------------

If the engine is running rough and you suspect air has been trapped in the fuel system, (e.g. the engine was allowed to run out of fuel) perform the following steps using qualified personnel:

1. Fully open the a ir bleeding valve by turning it counter clockwise, it is located on top of the fuel injection pump next to the oil filler. (see figure D.1)

Air Bleeding Valve

1. P roper op e r a t ion of the idler requires g o od

grounding of the Engine Control Unit, current sensing printed circuit board and battery.

2. 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.

FIGURE D.1

2. Turn the engine by pressing the start button until

the engine runs smoothly (this should take approximately 10 seconds).

3. Fully close the air bleeding valve by turning it

clockwise.

Contact your Kubota Engine repair facility if problems persist.

PIPELINER® 200D KUBOTA

Page 19

If necessary use shorter periods.

These preventive maintenance periods apply to average conditions of operation.

Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.

(3) Fill slowly! Ensure correct quantity is used.

(2) Consult Engine Operators Manual for additional maintenance schedule information.

(1) Consult Engine Operators Manual for oil recommendations.

Notes:

ENGINE SERVICE

S25833

R = ReplaceC = CleanI = Inspect

EVERY DAY OR EVERY 8 HOURS

FIRST SERVICE (50 HOURS)

EVERY 100 HOURS OR 3 MONTHS

EVERY 150 HOURS OR 4 MONTHS

EVERY 30O HOURS OR 9 MONTHS

EVERY 400 HOURS OR 12 MONTHS

EVERY 500 HOURS OR 15 MONTHS

EVERY 600 HOURS OR 18 MONTHS

ENGINE SERVICE (NOTE 2)

TYPE OR QUANTITY

locylG enelyhtE/retaW 05/05I

L0.9 ,.strq 5.9R

)retlif gnidulcni( L6.7 ,.strq 0.8RR

R I I

01079-08471 # atobuKR

575128P # nosdlanoDR

"6800.-"1700. tsuahxE ,"6800.-"1700. ekatnII I I

MAINTENANCE ITEM

Coolant (NOTE 3)

Fuel filter canister

Coolant level Concentration of antifreeze

Tension of alternator drive belt

Engine oil level (NOTE 1) Engine oil (NOTE 1 & 3) Engine oil filter Drain water separator & fuel strainer

Alternator drive belt wear Alternator drive belt Air filter (earlier check may be req'd) Air filter element

Leaks or engine damage Battery

Valve clearances Electrical systems All nuts and bolts for tightness

MAINTENANCE

D-3D-3

PIPELINER® 200D KUBOTA

Page 20

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PIPELINER® 200D KUBOTA

Page 21

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

Machine fails to hold the output (heat) consistently.

Welder starts but fails to generate current.

1. Rough or dirty commutator.

2. Brushes may be worn down to Limit.

3. Field circuit may have variable resistance connection or intermit t ent o p en cir cuit d u e to loose connection or broken wire.

4. Electrode lead or work lead connection may be poor.

5. Wrong grade of brushes may have been installed on generator.

6. Field rheostat may be making poor contact and overheating.

1. Generator or exciter brushes may be loose or missing.

2. Exciter may not be operating.

3. Field circuit of generator or exciter may be open

4. Exciter may have lost excitation.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

5. Series field and armature circuit may be open-circuited.

Welding arc is loud and spatters excessively.

Welding current too great or too small compared to indication on the dial.

Arc continuously pops out.

Flashing the exciter field consists of passing current through the fields using an external source of 6 to 125 volts of DC power from a storage battery or DC generator. If using a DC generator, keep the generator turned off except when actually applying the flashing current. To flash the fields:

1. Turn the welder off. Raise one exciter brush off the commutator.

2. On Lincoln welders, attach the positive lead from the external DC source to the right hand brushholder.

3. Carefully holding an insulated section of the negative lead from the DC source, touch its lug or clamp to the left hand brushholder for five seconds. Pull it away quickly to minimize arcing.

Remove the lead from the right hand brushholder, replace the brush on the commutator, start the welder and the voltage should build up.

1. Curr ent setti ng m ay be to o high.

2. Polarity may be wrong.

1. Exciter output low causing low output compared to dial indication.

2. Operating speed too low or too high.

1. “Current Range Selector” switch may be set at an intermediate position.

generator

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PIPELINER® 200D KUBOTA

Page 22

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-3

RECOMMENDED

COURSE OF ACTION

Engine does not start.

Engine does not turn over.

Irregular running of the engine.

1. Lack of fuel.

2. Air mixed in the fuel system.

3. Clogged fuel filter.

4. Irregular and faulty fuel supply (Injector pump trouble).

5. Glow plug not heated.

6. Clogged air cleaner.

7. No compression.

8. Engine protection light is ON.

1. Faulty Ignition switch and or Injector pump solenoid.

2. Insufficient charging or complete discharge of the battery.

3. Improper viscosity of the lubricating oil.

1. Air mixed in the fuel system.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

2. Uneven fuel injection (Faulty fuel injector pump).

3. Clogged fuel filter.

4. Defective governor.

5. Engine itself defective.

Engine stops during operation and the Engine Protection light does not turn on.

Engine stops during operation and the Engine Protection light does turn on.

1. Lack of fuel in the fuel tank.

2. Clogged fuel filter.

3. Air mixed in the fuel system.

4. Faulty function of the engine.

See Light Code Diagnoses Attached.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PIPELINER® 200D KUBOTA

Page 23

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE

E-4

LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM) ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY

LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND LOW OIL - CHECK OIL LEVEL ON DIPSTICK

LONG 1, SHORT 3 "L" TERMINAL IS GROUNDED ON ALTERNATOR BROKEN OR LOOSE BELT

FOR 1 SECOND LEAD TO "L" TERMINAL ON ALTERNATOR MAYBE

LONG 1, SHORT 4 HIGH WATER TEMPERATURE DETECTED AMOUNT OR QUALITY OF COOLANT INCORRECT

FOR 1 SECOND - CHECK

LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS

LONG 2, SHORT 1 0 RPM IS DETECTED AND 12V IS DETECTED FAULTY RPM SENSOR-CHECK FOR GOOD CONNECTION

FROM "L" TERMINAL ON ALTERNATOR FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD

LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT FAULTY ACTUATOR - CHECK FOR PROPER COIL

LONG 2, SHORT 3 NOT ENABLED FOR LINCOLN PRODUCTS

PLUNGER PULLS IN WHEN ENERGIZED

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

SHORTED TO GROUND- CHECK FAULTY ALTERNATOR - 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

TO RPM SENSOR FROM ECU

RESISTANCE LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED

- CHECK

LONG 2, SHORT 4 -50C WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR - CHECK FOR

LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR - CHECK FOR

LONG 2, SHORT 6 0 VOLTS DETECTED FROM "L" TERMINAL ON LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN

ALTERNATOR FOR 1 SECOND - CHECK FOR CONTINUITY

LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR INCORRECT BATTERY - INSPECT

LONG 2, SHORT 8 LESS THAN 4 VOLTS TO RPM SENSOR AND/OR FAULTY ECU -CHECK FOR 12 VOLTS ON LEADS TO RPM

ACTUATOR SENSED BY ECU SENSOR AND ACTUATOR FROM ECU

PROPER RESISTANCE

LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN

- CHECK FOR CONTINUITY

PROPER RESISTANCE LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK

BROKEN OR LOOSE BELT - INSPECT FAULTY ALTERNATOR - CHECK

FAULTY ALTERNATOR - CHECK

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PIPELINER® 200D KUBOTA

Page 24

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-5

RECOMMENDED

COURSE OF ACTION

White or Blue Smoke.

Dark Grey Smoke.

Faulty Charging.

1. Excess engine oil.

2. Too low v i s c o s i t y o f th e engine oil.

3. Faulty injection timing.

1. Unsuitable fuel.

2. Excess injection.

3. Faulty function of the engine.

4. Overloading.

5. Clogged air cleaner.

1. Loose fan belt.

2. Faulty wiring.

3. Faulty battery.

4. Worn out alternator brush.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Starter Motor does not run.

Engine Protection Light not coming on.

1. Loose or damaged wiring.

2. Drained voltage from battery.

3. Damaged starter m o t o r (including solenoid).

1. Broken Light Bulb.

2. Faulty light wiring.

3. Faulty Engine Control Unit.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PIPELINER® 200D KUBOTA

Page 25

E-6

TROUBLESHOOTING

ELECTRONIC IDLER TROUBLESHOOTING GUIDE

With Idler Control Switch in the Auto Position,

Engine Will Not Return to Low Idle in Approximately 15 Seconds

After Welding and Auxiliary Loads are Removed

Set Idler Control Switch

to the Auto Position

Check for Continuity through Idler

Control Switch

Open Closed

Check Voltage across Replace Idler

Idler Control switch Control Switch

E-6

12 VDC 0 VDC

Contact Kubota Replace current

Engine Repair Sensing PCB Facility

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PIPELINER® 200D KUBOTA

Page 26

E-7

TROUBLESHOOTING

ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE

With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When:

The Arc is Struck Both Auxiliary Load

E-7

Check for loose or disconnected

wire running between weld

selector switch and output stud.

1. Check Idler circuit wiring. The direction of leads entering the current sensor may be incorrect.

2. Check Idler circuit w i r i n g . P o s s i b l e Problems are wires from Current Sensing Board reversed at idler switch or wires connected incorrectly at Current Sensor Molex plug.

3. Check voltage across idler control switch.

12V 0V

Replace Current Contact Kubota Sensing PCB Engine Repair

Facility.

1. Load too small. Tr y load above 100 Watts.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

PIPELINER® 200D KUBOTA

Page 27

F-1

DIAGRAMS

F-1

PIPELINER® 200D KUBOTA

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 28

F-2

DIAGRAMS

F-2

PIPELINER® 200D KUBOTA

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 29

F-3

DIAGRAMS

F-3

PIPELINER® 200D KUBOTA

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 30

F-4

S26097

ORANGE

WHI

TE JUM

PER

WHI

TE JUM

PER

CABLE CONNECTION TABLE

LEAD COLOR RED

BLUE

CCW

BLUE

RED

ORANGE

K2464-

REMOTE

CONT

ROL

RING / CONNECT

ION DI

AGRAM

CONNECT TO CASE

RESISTORS

REMOTE CONTROL BOX

CV “WIRE” CONTROL POT

CC “STICK” CONTROL

DIAGRAMS

F-4

PIPELINER® 200D KUBOTA

Page 31

F-5

S10766-13

A.01

24.00

37.12 942

.85

68.00

1727.2

.00

660.

.75

349.25

4.0

101.

4.00

23.

584

209.55

41.66

3.25

82.55

57.7

1465.58

O. 56 S

KID

O.56

SKI

N.B.

20.62

523.

.50469.

40.94

103

9.88

45.50

N,A. CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT ON FUEL.

N.B. 56/14.2 TRAILER MOUNTING HOLES.

MONTING HOLE

DIMENSION PRINT

F-5

PIPELINER® 200D KUBOTA

Page 32

NOTES

PIPELINER® 200D KUBOTA

Page 33

NOTES

PIPELINER® 200D KUBOTA

Page 34

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 35

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 36

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric 11498 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual