Lincoln Electric 11498 User Manual
PIPELINER®200D KUBOTA
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200D
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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
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
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
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the 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.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. 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.
___________________________________________________
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.
___________________________________________________
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.
ii
SAFETY
ii
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
to
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.
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.
iv
SAFETY
iv
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.
TThhaannkk YYoouu
vv
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.
vi
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
________________________________________________________________________
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
________________________________________________________________________
Accessories.....................................................................................................Section C
Optional Features (Field Installed) ........................................................................C-1
Wire Feed Options.................................................................................................C-1
________________________________________________________________________
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
________________________________________________________________________
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
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagram ...................................................................................F-1,F-2,F-3,F-4
Dimension Print......................................................................................................F-5
________________________________________________________________________
Parts List.....................................................................................................P-504 Series
vi
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
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
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
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).
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