Lincoln Electric PIPELINER 200 User Manual

SVM193-A

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July, 2009

For use with machines having Code Numbers: 11114, 11316, 11471

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO

NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most

importantly, think before you act and be careful.

PIPELINER 200

®

10929, 10660, 10913, 11136

View Safety Info View Safety Info View Safety Info View Safety Info

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i 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

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

____________________________________________________

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

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.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 flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

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

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

2.d.1.

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

2.d.2. Never coil the electrode lead around your body.

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

___________________________________________________

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

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2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

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

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

Mar ʻ95

PIPELINER® 200

ii ii

SAFETY

ELECTRIC SHOCK can kill.

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

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

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

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

3.f.

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

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

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

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

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

ARC RAYS can burn.

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

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

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

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

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

5.c.

Do not weld in locations near chlorinated hydrocarbon 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.

vapors

to

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

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Jan ʻ09

PIPELINER® 200

iii iii

SAFETY

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a. this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjcent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

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

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

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

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 increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

Remove fire hazards from the welding area.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders

If

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

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

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

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

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

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

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

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

FOR ELECTRICALLY powered equipment.

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

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.

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

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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Jan ʻ09

PIPELINER® 200

iv iv

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

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

b. Faire trés attention de bien sʼisoler de la masse quand on

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

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

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

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

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

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

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

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

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

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

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.

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

10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

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

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

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a. Utiliser un bon masque avec un verre filtrant approprié ainsi

quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

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

PIPELINER® 200

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

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.

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

Mar ʻ93

I I

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv

Installation (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Installation (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section AA

Installation (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section AAA

Operation (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Operation (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BB

Operation (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BBB

Accessories (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Accessories (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section CC

Accessories (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section CCC

Maintenance (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Maintenance (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DD

Maintenance (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DDD

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual (GM 3.0 L) (K6090-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-370

Parts Manual (Perkins 104.22) (K6090-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-448

Parts Manual (Kubota V2203M) (K6090-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P504

PIPELINER® 200

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

General Description & Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Pre-Operation Installation & Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Trailer, Polarity Controls, Oil, Fuel & Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

TABLE OF CONTENTS - INSTALLATION SECTION

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PIPELINER® 200D KUBOTA

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - PIPELINER® 200D KUBOTA (K6090-11)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

4 Cylinder 4 Cycle 134.1 cu. in

Naturally Aspirated (2.2 ltrs) (Group 45, 650 57 L

Kubota Water-Cooled High Idle 1600 cold crank amps)

V2203M Diesel Engine Low Idle 1400 Bore x Stroke

Cast Iron Cylinder, Full Load 1600 40 A. Alternator 7.6 L

Block/Crankcase 3.43” x 3.64” w/ built in reg. 9.5 Qts

27.8HP @1600 RPM

12VDC battery

1.4 KW

Starter Oil: 8.0 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

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

Pure DC Power Generator

LINCOLN PLUS RATING

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

in. 24.00 in. 68.00 in. 1302 lbs.

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PIPELINER® 200D KUBOTA

A-3 A-3

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.

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:

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

This unit uses the Kubota V2203M Industrial water cooled diesel engine.

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.

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.

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

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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.

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

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

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

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

PIPELINER® 200D KUBOTA

A-4 A-4

INSTALLATION

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PRE-OPERATION INSTALLATION

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at the

front of this operatorʼs manual.

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

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.

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CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, the surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not more than 5.90”(150mm) beyond the equipment on all sides.

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

MACHINE GROUNDING

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

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

LIFT BAIL

A lift bail is provided for lifting with a hoist.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

• Do not lift machine if lift bale is EQUIPMENT can damaged.

• Do not operate machine while suspended from lift bale.

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

PIPELINER® 200D KUBOTA

A-5 A-5

TRAILER (See Accessories Section)

If the user adapts a non-Lincoln trailer, the user must assume responsibility that the method of attachment and usage does not result in a safety hazard nor 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

WARNING

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

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

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

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

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

• Follow vehicle manufactureʼs instructions.

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

INSTALLATION

RECOMMENDED COPPER CABLE SIZES

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

200 60% 1 1/0

PRE-OPERATION SERVICE

READ the engine operating and maintenance instruc-

tions supplied with this machine.

(1)

DIESEL FUEL

can

cause fire

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

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 manufacturerʼs recommendations. Upon receipt of the welder, check the engine dipstick to be sure the oil is at the “full” mark. DO NOT overfill.

Cables Sizes for Combined Length of Electrode Plus Work Cable

(61 to 76m)

CAUTION

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow fumes to clear before starting engine.

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

DIESEL FUEL ONLY

FUEL

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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 pos- itive 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.

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Fill the fuel tank with the grade of fuel recommended in the Engine Operatorʼs manual. Make sure the valve on the water separator is in the open position.

COOLING SYSTEM

The radiator has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed (see engine manual or antifreeze container for alternate antifreeze recommendations).

PIPELINER® 200D KUBOTA

A-6 A-6

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.

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.

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PIPELINER® 200D KUBOTA

B-1 B-1

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

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Idler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

TABLE OF CONTENTS - OPERATION SECTION

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PIPELINER® 200D KUBOTA

B-2 B-2

OPERATION

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ENGINE OPERATION

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at the

front of this operatorʼs manual.

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

STARTING THE PIPELINER® 200D KUBOTA V2203M DIESEL ENGINE

1. Turn the “IDLER” switch to “HIGH”.

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

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

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

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

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

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

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COLD WEATHER STARTING:

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

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

Under NO fluids be used!

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

HIGH ALTITUDE OPERATION:

At higher altitudes, output derating may be necessary. For maximum rating, derate the welder 4% for every 300 meters (984 ft.) above 1500 meters (4920 ft.).

Contact a Kubota Service Representative for any engine adjustments that may be required.

STOPPING THE ENGINE

1. Turn the “IGNITION” switch to “OFF”

At the end of each dayʼs welding, check the crankcase oil level, drain accumulated dirt and water from the water separator and refill the fuel tank to minimize moisture condensation in the tank. Also, running out of fuel tends to draw dirt into the fuel system.

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

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

ENGINE BREAK-IN

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

PIPELINER® 200D KUBOTA

WARNING

conditions should ether or other starting

B-3 B-3

OPERATION

Larger machines with a capacity of 350 amperes and higher, which are operated at low or no-load conditions for extended periods of time are especially susceptible to the conditions described above. To accomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engineʼs early life. However, if the welder is subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be necessary. Caution must be observed in correctly loading a diesel/generator unit.

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

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

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

WELDER OPERATION

WARNING

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and

ground.

FUMES & GASES can be dangerous.

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

DUTY CYCLE

The NEMA output rating of the PIPELINER® 200D KUBOTA is 200 amperes at 28 arc volts on cycle (consult Specifications in this manual 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% duty

for alternate

CAUTION

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

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

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

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

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

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

CAUTION

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ARC RAYS can burn.

• Wear eye, ear, and body protection.

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

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

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

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

PIPELINER® 200D KUBOTA

B-4 B-4

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.

OPERATION

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 V2203M DIESEL ENGINE

TYPICAL FUEL CONSUMPTION DATA

Low idle (1400 RPM ) .32gal/hr (1.21ltrs/hr ) No Load

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High idle ( 1600 Rpm ) .37gal/hr (1.40ltrs/hr ) No load

200 Amps @ 28 Volts .85gal/hr (3.22ltrs/hr )

Auxiliary Power 1,750 Watts .50gal/hr (1.89ltrs/hr)

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PIPELINER® 200D KUBOTA

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

TABLE OF CONTENTS - ACCESSORIES SECTION

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PIPELINER® 200D KUBOTA

C-2 C-2

ACCESSORIES

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 volt-

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

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

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

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

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

For lighter weight and easier handling. Rated 250 amps, 60% duty cycle. For .068 through 5/64” (1.7 through 2.0 mm) Innershield wire and includes reduced speed switch. For pipewelding, an M11476 62° gun tube is recommended.

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.

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PIPELINER® 200D KUBOTA

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions, Bearings, Commutator & Brushes, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Idler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

TABLE OF CONTENTS - MAINTENANCE SECTION

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PIPELINER® 200D KUBOTA

D-2 D-2

MAINTENANCE

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 operatorʼs manual.

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

GENERAL INSTRUCTIONS

1. Blow out the welder and controls with an air hose at

least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation.

2. “Current Range Selector” contacts should not be

greased. To keep the contacts clean, rotate the current control through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld.

4. When necessary, remove the sediment bowl, if so

equipped, from beneath the fuel tank and clean out any accumulated dirt and water.

5. Follow the engine service schedule in this manual

and the detailed maintenance and troubleshooting in the engine manufacturerʼs manual.

COOLING SYSTEM

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

BEARINGS

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

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

COMMUTATOR AND BRUSHES

WARNING

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

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

Shifting of the commutator brushes may result in:

- Change in machine output

- Commutator damage

- Excessive brush wear

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

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

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shaft at least once every month.

PIPELINER® 200D KUBOTA

D-3 D-3

MAINTENANCE

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 RGI NG AI R FR OM FU EL SY STE M (KUBOTA V2203M ENGINE)

WARNING

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

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

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

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

Air Bleeding Valve

1. Proper operation of the idler requires good ground-

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

2. If desired, the welder can be used without automat-

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 clock-

wise.

Contact your Kubota Engine repair facility if problems persist.

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PIPELINER® 200D KUBOTA

D-4 D-4

If necessary use shorter periods.

These preventive m

aintenance periods apply to average conditions of operation.

Above operations to be carried out by trained personnel with reference to the worksh

op 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 Ma

nual for oil recommendations.

Notes:

ENGINE SERVICE

S25833

R = Replace

C = Clean

I = Inspect

EVER Y DAY O R EV ERY 8 HO URS

F

IRST SERVICE (50 HOURS)

E

VERY 100 HOURS OR 3 MONTHS

EVERY 150 HO URS OR 4 M O NTHS

E

VERY 30O HOURS OR 9 MONTHS

EVERY 400 HOURS O R 12 MONTHS

EVERY 500 HO URS OR 15 MONTHS

EVERY 600 HOURS OR 18 MONTHS

ENGINE SERVICE (NOTE 2)

TY PE OR QUANTITY

I

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y

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eta

W

05/0

5I

L0.9,.strq5.9R

I

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etl

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RR

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01079-08471

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575128P#nosdlanoDR

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MAINTENANCE ITEM

C

oolant (NOTE 3)

Fuel filter canister

Coolant level Concentration of antifreeze

Tension of alt ernator dri ve belt

Engine oil level (NOTE 1) Engine oil (NOTE 1 & 3) Engine oil filter Drain water s eparator & fuel strai ner

Alternator drive belt wear Alternator drive belt Air filter (earlier c hec k may be req'd) Air filter element

Leaks or engine damage Battery

Valve clearances Electrical systems All nuts and bolts for tightness

MAINTENANCE

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PIPELINER® 200D KUBOTA

D-5 D-5

99

88

11

55

77

44

66

33

66

99

22

MAINTENANCE

1. Case Front Assembly

2. Engine Assembly

3. Exciter Frame, Armature Assembly

4. Generator Frame, Armature & Coupling

5. Fuel Tank Assembly

6. Generator & Exciter Brush Holder Assemblies

7. Base & Lift Bale Assembly

8. Radiator Assembly

9. Roof & Doors

Figure D.2 - Major Component Location

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PIPELINER® 200D KUBOTA

D-6 D-6

NOTES

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PIPELINER® 200D KUBOTA

AA-1 AA-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-3

Trailers, Polarity Control & Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-4

Oil, Fuel, Cooling System & Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-5

TABLE OF CONTENTS - INSTALLATION SECTION

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PIPELINER® 200D PERKINS

AA-2 AA-2

INSTALLATION

TECHNICAL SPECIFICATIONS - Pipeliner® 200D (K6090-9)

INPUT - DIESEL ENGINE

Make/Model Description Horsepower Operating

SPEED System

Perkins

104.22

4 Cylinder

4 Stroke

Naturally

Aspirated

Water Cooled Engine

28.2 HP

@ 1600RPM

High

1600RPM

Full Load

1550RPM

Low Idle

1400RPM

RATED OUTPUT @ 104°F(40C°) - WELDER

DESCRIPTION

200 Amp DC Welder

All Copper Windings

Pure DC Power

Generator

RATED DC OUTPUT

VOLTS @ RATED AMPS

Lincoln Plus Rating

40V @ 200A

NEMA Rating

28V @ 200A

Displacement

135.6 (2.2)

DUTY CYCLE*

60%

cu. in.(ltrs)

Starting Capacities

12VDC Battery

and starter

Push Button

Starter

(650 Cold

crank amps)

DC CURRENT RANGE

Fine Adjustment in each Range

40-300 Amps

Fuel:

15gal.

Oil: 8.7 qts.

(8.2L)

Radiator Coolant

9.5 qts. (9.0L)

(57L)

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

Auxiliary Power1*

1.80 kW, 15 Amps @ 120V DC @ 35% Duty Cycle

ENGINE COMPONENTS

LUBRICATION FUEL SYSTEM GOVERNOR

Full Pressure with Full Flow Filter Indirect Fuel Injector Mechanical Governor

Electrical Shutoff Solenoid Mechanical Fuel Pump

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Shutdown on low oil

Single Element Automatic Idler Made from long life, pressure and engine

aluminized steel. temperature.

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

40.94** in. 24.00 in. 66.50in.

1039.9 mm 609.6 mm 1689.1 mm 1318 lbs. (598 kg.)

**Top of enclosure, add 8.0” (203.2mm) for exhaust

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

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* Based on a 10 minute period.

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PIPELINER® 200D PERKINS

AA-3 AA-3

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operatorʼs manual.

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

EXHAUST SPARK ARRESTER

Some federal, state, or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard mufflers included with these welders do not qualify as spark arresters. When required by local regulations, suitable spark arrester must be installed and properly maintained.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, the surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not more than 5.90”(150mm) beyond the equipment on all side.

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

MACHINE GROUNDING

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

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

LIFT BAIL

A lift bail is provided for lifting with a hoist.

WARNING

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CAUTION

Use of an incorrect arrester may lead to engine damage or performance loss. Contact the engine manufacturer for specific recommendations.

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

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.

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• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

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

PIPELINER® 200D PERKINS

AA-4 AA-4

INSTALLATION

TRAILERS (See ACCESSORIES SECTION)

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

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

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

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

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

POLARITY CONTROL AND CABLE SIZES

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

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

RECOMMENDED COPPER CABLE SIZES

Cable Sizes for Combined

Length of Electrode Plus

Work Cable

Amps

200

Duty Cycle

60%

Up to 200 ft1200-250 ft

1/0

5. Conformance with federal, state, and local laws.

(1)

Consult applicable 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 manufactureʼs instructions.

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

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance instructions supplied with this machine.

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

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow

DIESEL FUEL

can

cause fire

fumes to clear before starting engine.

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

DIESEL FUEL ONLY

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

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PIPELINER® 200D PERKINS

AA-5 AA-5

INSTALLATION

OIL

This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the engine operation manual for specific engine manufacturers recommendations. Upon receipt of the welder, check the engine dipstick to be sure the oil is at the “full” mark. Add if required. DO

NOT OVERFILL.

FUEL

Fill the fuel tank with the grade of fuel recommended in the Engine Operatorʼs Manual. Make sure fuel valve on the sediment bowl and water separator are in the open position.

COOLING SYSTEM

The radiator has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed. (See engine manual or antifreeze container for alternate antifreeze recommendations.)

BATTERY CHARGING

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.

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

When replacing, jumping, or otherwise connecting the battery to the battery cables the proper polarity must be observed. The correct polarity is NEGATIVE

GROUND.

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PIPELINER® 200D PERKINS

AA-6 AA-6

NOTES

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PIPELINER® 200D PERKINS

BB-1 BB-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-1

Safety Precautions & Design Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-2

Engine Operation & Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-3

Welder Operation & Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-4

Idler Operation & Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BB-5

TABLE OF CONTENTS - OPERATION SECTION

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PIPELINER® 200D PERKINS

BB-2 BB-2

OPERATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

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

RATED OUTPUT DUTY CYCLE

200A @ 28V 60% 200A @ 40V 60%

The unit is also capable of providing 1.80 kw of 120V DC auxiliary power at 35% duty cycle maximum.

This unit uses the PERKINS 104.22 Industrial water cooled diesel engine.

DESIGN SUMMARY

Control Panel

Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine. The welder controls consist of a five step “Current Range Selector” switch and a “Fine Current Adjustment” rheostat. The welder is equipped with a “Start” button,”Glow Plug” button, “Ignition” switch, “Idler” control switch, hour meter, “Engine Protection” indicator light, “Remote / Local Switch and Receptacle a battery charging ammeter, an oil pressure gauge and engine coolant temperature gauge.

See additional warning information at

front of this operatorʼs manual.

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

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

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

GENERAL DESCRIPTION

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

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

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

The control panel also contains a three prong grounding type receptacle for auxiliary power.

Welding Generator

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

Engine Idler

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

Auxiliary Power

1.80 kw of nominal 120V DC auxiliary power at 35% duty cycle maximum. Output voltage is maintained within ± 10% at all loads up to rated capacity.

Welder Enclosure

The complete welder is rubber mounted on a rugged steel “C” channel base.

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The output terminals are placed at the side of the machine so that they are protected by the door. The output terminals are labeled (+) and (-).

PIPELINER® 200D PERKINS

BB-3 BB-3

OPERATION

Cranking System

A 12V electric starter is standard.

Air Cleaner

Heavy duty two-stage dry type

Exhaust

A muffler and stainless steel exhaust outlet pipe are standard.

Engine Hour Meter

A meter to record the hours of operation.

ENGINE OPERATION

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

STARTING THE PIPELINER® 200D PERKINS

104.22 DIESEL ENGINE

1. Turn the “IDLER” switch to “HIGH”.

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

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

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

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

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

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

COLD WEATHER STARTING

With a fully charged battery and a proper weight oil, the engine should start satisfactorily even down to about 15°F -(26°C). If the engine must be frequently started at or below -15°F -(26°C), it may be desirable to install cold-starting aides. Note: Extreme cold weather starting may require longer glow plug operation

WARNING

Under NO fluids be used!

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

STOPPING the ENGINE

1. Turn the “IGNITION” switch to “OFF”

At the end of each dayʼs welding, check the crankcase oil level, drain accumulated dirt and water from the sediment bowl under the fuel tank and refill the fuel tank to minimize moisture condensation in the tank. Also, running out of fuel tends to draw dirt into the fuel system.

When hauling the welder between job sites, close the fuel feed valve beneath the fuel tank.

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

PIPELINER® 200D WITH PERKINS 104.22 DIESEL ENGINE

Low idle (1400 RPM ) .33gal/hr (1.25ltrs/hr ) No Load High idle ( 1800 Rpm ) .39gal/hr (1.48ltrs/hr ) No load 200 Amps @ 28 Volts .67gal/hr (2.54ltrs/hr )

200 Amps @ 40 Volts .75gal/hr (2.84ltrs/hr ) Auxiliary Power 15 Amps @ 120 Volts .50gal/hr (1.89ltrs/hr)

conditions should ether or other starting

TYPICAL FUEL CONSUMPTION DATA

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PIPELINER® 200D PERKINS

BB-4 BB-4

OPERATION

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.

Larger machines with a capacity of 350 amperes and higher, which are operated at low or no-load conditions for extended periods of time are especially susceptible to the conditions described above. To accomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engineʼs early life. However, if the welder is subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be necessary. Caution must be observed in correctly loading a diesel/generator unit.

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

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

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

WELDER OPERATION

WARNING

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground.

FUMES & GASES can be dangerous.

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

DUTY CYCLE

The NEMA output rating of the Pipeliner® 200D is 200 amperes at 28 cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period.

(1)

The “Lincoln Plus” output rating at 60% duty cycle is 200 amperes at 40 Volts.

(1)

arc volts on a 60% duty cycle. Duty

CONTROL OF WELDING CURRENT

CAUTION

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

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

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

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

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PIPELINER® 200D PERKINS

BB-5 BB-5

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

OPERATION

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.

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 idler solenoid acti- vates, and the engine goes to high idle speed. The speed is controlled by the governor.

2. In the “Auto” / position, the idler oper- ates as follows:

When welding or drawing power for lights or tools

•

(approximately 100-150 watts minimum) from the receptacle, the idler solenoid activates and the engine operates at high idle speed.

• When welding ceases or the power load is turned off,

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

• If the welding or power load is not re-started before the

end of the time delay, the idler solenoid deactivates and reduces the engine to low idle speed.

AUXILIARY POWER

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1.80 kW of 120V DC auxiliary power at 35% duty cycle maximum is available at the receptacle located on the control panel.

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PIPELINER® 200D PERKINS

BB-6 BB-6

NOTES

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PIPELINER® 200D PERKINS

CC-1 CC-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CC-1

TABLE OF CONTENTS - ACCESSORIES SECTION

Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CC-2

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PIPELINER® 200D PERKINS

CC-2 CC-2

ACCESSORIES

OPTIONAL FEATURES (Field Installed)

Accessory Set (K704) - Includes electrode and work

cables, headshield, work clamp and electrode holder.

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

Remote Control Kit (K2464-1) - Contains a remote control rheostat (for adjusting CC “STICK” OCV), remote control potentiometer (for adjusting CV “STICK” OCV) and 100ft. (30.5m) cable. (See Wiring/Connection Diagram Section)

Trailer (K957-1) - Two-wheeled trailer for in-plant and yard towing at speeds under 20 mph only.

Trailer (K953-1) - Two-wheeled trailer with optional fender and light package. For highway use, consult applicable federal, state, and local laws regarding possible additional requirements. Choice of 2 hitches and add on fender & light package. Order: K953-1

Trailer, K958-1 Ball Hitch, K958-2 Lunette Eye Hitch, K959-1 Fender & Light Kit.

Wire Feed Module (K623-1) - Provides constant volt-

age (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25.

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

Oil Drain Kit (K1586-1) - Includes ball valve, hose and clamp.

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.

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

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PIPELINER® 200D PERKINS

DD-1 DD-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-2

Bearings, Commutator & Brushes, Idler Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-3

Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-4

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DD-5

TABLE OF CONTENTS - MAINTENANCE SECTION

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PIPELINER® 200D PERKINS

DD-2 DD-2

MAINTENANCE

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.

4. When necessary, remove the sediment bowl from beneath the gas tank and clean out any accumulated dirt and water. Replace the fuel filter in the fuel line as needed.

5. See the engine manufacturers operation manual for detailed engine maintenance and troubleshooting instructions.

COOLING SYSTEM

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

ENGINE MAINTENANCE

Refer to the Engineʼs operation and maintenance manual for additional information on the engine.

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operatorʼs manual.

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

GENERAL INSTRUCTIONS

1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation.

2. “Current Range Selector” contacts should not be greased. To keep the contacts clean, rotate the current control through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld.

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3. Put a drop of oil on the “Current Range Selector” shaft at least once every month.

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PIPELINER® 200D PERKINS

DD-3 DD-3

MAINTENANCE

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.

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

The generator brushes are properly adjusted when the welder is shipped. They require no particular attention. DO NOT SHIFT THE BRUSHES or adjust the rocker setting. Shifting of the brushes may result in:

• Change in machine output

• Commutator damage

• Excessive brush wear

Periodically inspect the commutator and brushes by removing the covers. DO NOT remove or replace these covers while the machine is running.

Commutators require little attention. However, if they are black or appear uneven, have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Never use emery cloth or paper for this purpose.

IDLER MAINTENANCE

CAUTION

Before doing electrical work on the idler printed circuit board, disconnect the battery.

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

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

1. The solenoid plunger must work freely and not bind.

Dust the plunger about once a year with graphite powder.

2. Proper operation of the idler requires good ground-

ing of the printed circuit board, current sensor and battery.

3. Idler solenoid is activated for high idle.

4. If desired, the welder can be used without automat-

ic idling by setting the “Idler” switch to the “High” position.

NAMEPLATES

Whenever routine maintenance is performed on this machine - or at least yearly - inspect all nameplates and labels for legibility. Replace those which are no longer clear. Refer to the parts list for the replacement item number.

PURGING AIR from FUEL SYSTEM (Perkins 104.22 Engine)

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

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

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

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

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

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PIPELINER® 200D PERKINS

DD-4 DD-4

I

EVERY 400 HOURS OR 12 MONTHS

EVERY 200 HOURS OR 6 MONTHS

EVERY 100 HOURS OR 3 MONTHS

FIRST SERVICE-(20 / 50 HOURS)

EVERY DAY OR EVERY 8 HOURS

Perkins #140517000

If necessary use shorter periods.

These preventive maintenance periods apply to average conditions of operation.

Perkins #26560017

TYPE OR QUANTITY

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

9.5qrts., 9.0L

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

8.7qrts, 8.2L (including filter)

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

(1) Consult Engine Operators Manual for oil recommendations.

Notes:

Alternator drive belt

Alternator drive belt wear

R

Tension of alternator drive belt

Fuel filter canister

I

Drain water separator & fuel strainer

Engine oil (NOTE 1 & 3)

R

Engine oil level (NOTE 1)

Coolant (NOTE 3)

MAINTENANCE ITEM

Concentration of antifreeze

C

I

R

Coolant level

R

C

R

I

R

I

EVERY 600 HOURS OR 18 MONTHS

S25557

Contact Perkins

Intake .008", exhaust .008"

Donaldson #P181050, Nelson #70206N

R = ReplaceC = Clean

Battery

Leaks or engine damage

I

Injector performance

All nuts and bolts for tightness

I = Inspect

Electrical systems

I

Valve clearances

I

Tighten cylinder head

I

Check and adjust idle speed

I

Air filter element

Air filter (earlier check may be req'd.)

R

I

CC

Engine oil filter

ENGINE SERVICE (NOTE 2)

50/50 Water/Ethylene Glycol

Perkins #080109080

MAINTENANCE

1. Loosen by two or three turns, the vent screw (Figure DD.1) on the fuel inlet connection.

Vent Screw

FIGURE DD.1

2. Operate the electric fuel pump by turning the “Ignition” switch “ON” until fuel, free of air, flows from the vent point. Tighten the vent screw.

3. Contact your Perkins Engine repair facility if problems persist.

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PIPELINER® 200D PERKINS

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DD-5 DD-5

10

9

1

5

7

4

6

3

10

2

8

MAINTENANCE

1. Case Front Assembly

2. Engine Assembly

3. Exciter Frame, Armature Assembly

4. Generator Frame, Armature & Coupling

5. Fuel Tank Assembly

6. Generator & Exciter Brush Holder Assemblies

7. Base & Lift Bale Assembly

8. Idler Solenoid Assembly

9. Radiator Assembly

10. Roof & Doors

Figure DD.2 - Major Component Location

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PIPELINER® 200D PERKINS

DD-6 DD-6

NOTES

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PIPELINER® 200D PERKINS

AAA-1 AAA-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-3

Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-4

Pre-Operation Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AAA-5

TABLE OF CONTENTS - INSTALLATION SECTION

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PIPELINER® 200G

AAA-2 AAA-2

INSTALLATION

TECHNICAL SPECIFICATIONS - Pipeliner® 200G (K6090-7)

INPUT - GASOLINE ENGINE

Make/Model Description Speed (RPM) Displacement Ignition Capacities

cu. in. (Ltrs.) System

4 Cylinder High Energy

GM 4 Cycle Oil: 4.5Qts.(4.3L)

3.0 Liter Full Load 1600 Distributor Type

Pipeliner® 200G 183.0(3.0) Electronic

(K6090-7) 46 HP @

1600 RPM Low Idle 1360

High Idle 1600 Delco Voyager Fuel: 15gal.(57L)

Coolant: 9.9 Qts.

RATED OUTPUT - WELDER

DESCRIPTION

200 Amp DC Welder

All Copper Windings

Pure DC Power

Generator

RATED DC OUTPUT*

VOLTS @ RATED AMPS

Lincoln Plus Rating

40V @ 200A

NEMA Rating

28V @ 200A

DUTY CYCLE

60%

DC CURRENT RANGE

Fine Adjustment in each Range

40-300 Amps

OUTPUT - GENERATOR

Auxiliary Power

1.75 kW, 15 Amps @ 120V DC

1

(9.4L)

ENGINE OPERATING LOAD FUEL CONSUMPTION

Low Idle (1360 RPM)-No Load

High Idle (1600 RPM)-No Load

DC Auxiliary-128 Volts-15 Amps-1600 RPM

50 Amps @ 38 Volts @ 60% Duty Cycle

100 Amps @ 34 Volts @ 60 % Duty Cycle

150 Amps @ 29 Volts @ 60% Duty Cycle

200 Amps @ 40 Volts @ 60 % Duty Cycle

.7 gal/hr (2.8 ltrs/hr) .8 gal/hr (3.1 ltrs/hr)

1.1 gal/hr (4.0 ltrs/hr)

1.04 gal/hr (3.94 ltrs/hr)

1.12 gal/hr (4.25 ltrs/hr)

1.15 gal/hr (4.37 ltrs/hr)

1.34 gal/hr (5.07 ltrs/hr)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

40.94** in. 24.00 in. 68.16in.

1039.9 mm 609.6 mm 1731.0 mm 1295.0 lbs. (587kg.)

**Top of enclosure, add 4.6” (116.8mm) for exhaust

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

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PIPELINER® 200G

AAA-3 AAA-3

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operatorʼs manual.

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

PRE-OPERATION INSTALLATION

EXHAUST SPARK ARRESTER

Some federal, state, or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard mufflers included with these welders do not qualify as spark arresters. When required by local regulations, suitable spark arrester must be installed and properly maintained.

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 be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not more than 5.90”(150mm) beyond the equipment on all sides.

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

MACHINE GROUNDING

Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.).

To prevent dangerous electric shock, other equipment powered by this engine driven welder must:

• be grounded to the frame of the welder using a grounded type plug,

or

• be double insulated.

When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When this engine driven welder is connected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the section entitled “Standby Power Connections” as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

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CAUTION

Use of an incorrect arrester may lead to engine damage or performance loss. Contact the engine manufacturer for specific recommendations.

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

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In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

PIPELINER® 200G

AAA-4 AAA-4

INSTALLATION

ANGLE OF OPERATION

To achieve optimum engine performance the Pipeliner® 200G should be run in a level position. The maximum angle of operation for the engine is 60 degrees in a direction to cause the air intake manifold to be angled up, 45 degrees for the air intake manifold to be angled down; and 50 degrees for the welder control panel to be angled up or down. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase. When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 15 gallons.

LIFT BAIL

A lift bail is provided for lifting with a hoist.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

• Do not lift machine if lift bale is damaged. Equipment can be damaged or cause injury.

• Do not operate machine while suspended from lift bale.

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

5. Conformance with federal, state, and local laws.

(1)

Consult applicable 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 manufactureʼs instructions.

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

POLARITY CONTROL AND CABLE SIZES

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

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TRAILERS (See ACCESSORIES SECTION)

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

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

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

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

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

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

Amps

200

PIPELINER® 200G

RECOMMENDED COPPER CABLE SIZES

Cable Sizes for Combined

Length of Electrode Plus

Work Cable

Duty Cycle

60%

Up to 200 ft

(61.0m)

1

200-250 ft

(61.0-72.2m)

1/0

AAA-5 AAA-5

INSTALLATION

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance instruc-

tions supplied with this machine.

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

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow

GASOLINE

can cause fire or explosion.

fumes to clear before starting engine.

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

GASOLINE FUEL ONLY

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

OIL

This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the engine operation manual for specific engine manufacturers recommendations. Upon receipt of the welder, check the engine dipstick to be sure the oil is at the “full” mark. Add if required. DO

NOT OVERFILL.

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away.

BATTERY ACID can burn eyes and skin.

• Wear gloves and eye protection and be

careful when boosting, charging or working near battery.

To prevent EXPLOSION when:

a) Installing a new battery - disconnect the

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

b) Connecting a battery charger - remove the

battery from the welder by disconnecting the negative cable first, then the positive cable and battery clamp. When reinstalling, connect the negative cable last.

c) Using a booster - connect the positive lead to

the battery first, then connect the negative lead to

the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:

a) Installing a new battery. b) Using a booster.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, turn ignition switch off when engine is not running.

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FUEL

Fill the fuel tank with the grade of fuel recommended in the Engine Operatorʼs Manual. Make sure fuel valve on the sediment bowl is in the open position.

COOLING SYSTEM

The radiator has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed. (See engine manual or antifreeze container for alternate antifreeze recommendations.)

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• To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug.

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

BATTERY CHARGING

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

When replacing, jumping, or otherwise connecting the battery to the battery cables the proper polarity must be observed. The correct polarity is NEGATIVE

GROUND.

PIPELINER® 200G

AAA-6 AAA-6

NOTES

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PIPELINER® 200G

BBB-1 BBB-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-1

Safety Precautions & Design Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-2

Engine/Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-3

Control of Welding Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BBB-4

TABLE OF CONTENTS - OPERATION SECTION

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PIPELINER® 200G

BBB-2 BBB-2

OPERATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operatorʼs manual.

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

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

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

GENERAL DESCRIPTION

DESIGN SUMMARY

Control Panel

Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine. The welder controls consist of a five step “Current Range Selector” switch and a “Fine Current Adjustment” rheostat. The welder is equipped with a “Start” button, “Ignition” switch, “Idler” control switch, hour meter, a battery charging ammeter, an oil pressure gauge and engine coolant temperature gauge.

The control panel also contains a three prong grounding type receptacle for auxiliary power.

Welding Generator

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

Engine Idler

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

Auxiliary Power

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The Pipeliner® 200G is a heavy duty engine driven DC arc welding power source capable of providing DC constant current output for stick welding and DC TIG welding. With the addition of the optional K623-1 Wire Feed Module the Pipeliner® 200G will provide constant voltage output for running the LN-25 wire feeder.

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

RATED OUTPUT DUTY CYCLE

200A @ 28V 60% 200A @ 40V 60%

The units are also capable of providing 1.75 kw of 115V DC auxiliary power. This unit uses the GM 3.0L industrial water- cooled gasoline engine.

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1.75 kw of nominal 120V DC. Output voltage is maintained within ± 10% at all loads up to rated capacity. (See Optional Features for power plug kits).

Welder Enclosure

The complete welder is rubber mounted on a rugged steel “C” channel base.

The output terminals are placed at the side of the machine so that they are protected by the door. The output terminals are labeled (+) and (-).

Ignition System

A High Energy Distributor Type electronic ignition is standard.

PIPELINER® 200G

BBB-3 BBB-3

OPERATION

Cranking System

A 12V electric starter is standard.

Air Cleaner

Heavy duty two-stage dry type

Exhaust

A muffler and stainless steel exhaust outlet pipe are standard.

Engine Hour Meter

A meter to record the hours of operation.

High Idle RPM (OCV) Adjustment- A potentiometer is mounted on the output rail that allows the operator to adjust the high idle engine speed between 1500 and 1600 RPM in 20 RPM increments. This is to allow further adjustment of the OCV. Total OCV adjustment range is about 10 Volts.

ENGINE OPERATION

STOPPING THE ENGINE

• Turn the Ignition switch to “OFF”.

At the end of each dayʼs welding, refill the fuel tank to minimize moisture condensation in the tank. Also, running out of fuel tends to draw dirt into the fuel system.

When hauling the welder between job sites, close the fuel feed valve beneath the fuel tank. Refer to engine “Operation and Maintenance manual” for additional information on the engine supplied with this welder.

WELDER OPERATION

WARNING

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.

STARTING THE GM 3.0L ENGINE

• Turn the Idler control switch to “HIGH”. (Optional)

• Turn the Ignition switch to “ON”.

• Press the “Start” button.

• If the engine fails to start in 20 seconds, wait 30 seconds before repeating the above procedure.

• Allow the engine to run at high idle speed for several minutes to warm up. If idle control switch is left in “Auto” position , engine will run at 1600 RPM until engine coolant temperature reaches 130°F.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

DUTY CYCLE

The NEMA output rating of the Pipeliner® 200G is 200 amperes at 28 cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period.

(1)

The Lincoln “plus output” rating at 60% duty cycle is 200 amperes at 40 Volts.

(1)

arc volts on a 60% duty cycle. Duty

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PIPELINER® 200G

BBB-4 BBB-4

OPERATION

CONTROL OF WELDING CURRENT

CAUTION

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

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

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

A high open circuit voltage setting provides the soft “buttering” arc with the best resistance to pop-outs preferred for most welding. To get this characteristic, set the “Current Range Selector” to the lowest setting that still provides the current you need and set the 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 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.

amps.

“Fine

IDLER OPERATION

The operating speeds are as follows:

ORDERING

INFO.

K6090-7 GM 3.0L 1600-

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

1. In the “High” position, the idler is off, and the engine runs at the high speed controlled by the governor. This speed can be adjusted between 1500 and 1600 RPM using the RPM dial on the output rail.

2. In the “Automatic” / position, the idler operates as follows:

• When welding or drawing power for lights or tools

(approximately 100-150 watts minimum) from the receptacle, the engine operates at the speed, set by the RPM dial.

• When welding ceases or the power load is turned

off, a preset time delay of 10 seconds starts. This time delay cannot be adjusted.

ENGINE FULL

LOAD

1500

HIGH

IDLE

1600-

1500

LOW IDLE

1360

CAUTION

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

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

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

TBI DEICING SYSTEM

The welder has been designed to allow continuous year-round operation. Engine coolant is channeled through the TBI housing to prevent the build up of ice on the TBI throat around the throttle plate. the electronic controller is programmed to automatically compensate for the build up of ice on the throttle plate. There will be no noticeable change in the operation of the welder should icing develop. On start-up, there is a possibility for the engine to overspeed (to a maximum of 2000 RPM) for up to 10 seconds after throttle body icing conditions have occurred. The electronic governor will correct itself for the new operating conditions and normal operation will resume.

• If the welding or power load is not re-started before the end of the time delay, the idler reduces the engine to low idle speed.

AUXILIARY POWER

1.75 kw of 120V DC auxiliary power is available at the receptacle located on the control panel.

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PIPELINER® 200G

CCC-1 CCC-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CCC-1

Optional Equipment & Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CCC-2

TABLE OF CONTENTS - ACCESSORIES SECTION

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PIPELINER® 200G

CCC-2 CCC-2

ACCESSORIES

OPTIONAL EQUIPMENT

(K704) Accessory Set

Includes 35 ft (10.7m) electrode and 30 ft (9.1m) work cables, headshield, work clamp, and electrode holder.

(FIELD INSTALLED)

WARNING

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

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

(K924-4) REMOTE CONTROL

For machines having Code Number 10660: For “Stick” operation which contains switch, remote control rheostat and 100 ft (30.5m) or 25 ft (7.6m) cable. Easy Installation.

(K953-1) TRAILER - Two-wheeled trailer with

optional fender and light package. For highway use, consult applicable federal, state, and local laws regarding possible additional requirements. There is a choice of 2 hitches, a fender & a light package. Order:

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

(K623-1) WIRE FEED MODULE -Provides con-

stant voltage (CV) output with improved arc stability for Innershield welding. Also, excellent for MIG welding. Easy Installation. Recommended wire feeder is the LN-25.

(K2261-1) OIL DRAIN KIT-Includes ball valve,

hose and clamp.

(K924-5) REMOTE CONTROL

For machines having Code Number 10913: For “Stick” operation containing remote control rheostat and 100 ft (30.5m) cable. Easy Installation.

REMOTE CONTROL (K2464-1) - Contains

remote control rheostat (for adjusting the CC “STICK” OCV), remote control potentiometer (for adjusting the CV “WIRE” OCV), and 100 ft. (30.5m) cable. Easy

Installation.

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PIPELINER® 200G

DDD-1 DDD-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-2

Bearings, Commutator & Brushes, Idler Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-3

Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-4

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DDD-5

TABLE OF CONTENTS - MAINTENANCE SECTION

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PIPELINER® 200G

DDD-2 DDD-2

MAINTENANCE

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.

3. Change the crankcase oil and oil filter after the first 50 hours of operation and thereafter at regular intervals using the proper grade of oil. See the recommendations in the engine operation manual.

4. Inspect the air filter daily - - more often in dusty conditions when necessary clean or replace. The air filter should never be removed while the engine is running. The air filter element part number is Donaldson #181050 or Nelson #70206N.

5. When necessary, remove the sediment bowl from beneath the gas tank and clean out any accumulated dirt and water. Replace the fuel filter in the fuel line as needed. In an emergency, the fuel filter can be back-flushed for continued use until a replacement can be obtained.

6. Fan belts tend to loosen after the first 50 hours of operation. Check engine operation manual and tighten if necessary. DO NOT OVERTIGHTEN.

7. Put a drop of oil on the “Current Range Selector” shaft at least once every month.

8. See the engine manufacturers operation manual for detailed engine maintenance and troubleshooting instructions.

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at front of this operatorʼs manual.

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

GENERAL INSTRUCTIONS

1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation.

2. “Current Range Selector” contacts should not be greased. To keep the contacts clean, rotate the current control through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld.

COOLING SYSTEM

The Pipeliner® 200G is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the cooling system periodically to prevent clogging the passage and overheating the engine. When antifreeze is needed, always use the permanent type. Capacity = 9.9 Qty. (9.4 liter) Consult the engine owners manual for the proper frequency and procedure.

ENGINE MAINTENANCE

Refer to the Engineʼs operation and maintenance manual for additional information on the engine.

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PIPELINER® 200G

DDD-3 DDD-3

MAINTENANCE

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.

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

The generator brushes are properly adjusted when the welder is shipped. They require no particular attention. DO NOT SHIFT THE BRUSHES or adjust the rocker setting. Shifting of the brushes may result in:

IDLE CONTROL MAINTENANCE

CAUTION

Before doing electrical work on the idler printed circuit board, disconnect the battery.

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

1. Proper operation of the idler requires good grounding of the battery and TBI controller.

2. If desired, the welder can be used without automatic idling by setting the “Idler” switch to the “High Idle” position.

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

NAMEPLATES

Whenever routine maintenance is performed on this machine - - or at least yearly - - inspect all nameplates and labels for legibility. Replace those which are no longer clear. Refer to the parts list for the replacement item number.

PURGING AIR FROM FUEL SYSTEM

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• Change in machine output

• Commutator damage

• Excessive brush wear

Periodically inspect the commutator and brushes by removing the covers. DO NOT remove or replace these covers while the machine is running.

Commutators require little attention. However, if they are black or appear uneven, have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Never use emery cloth or paper for this purpose.

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

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

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The fuel system operates as follows: The fuel pump will operate for a maximum of 3 seconds when the ignition switch is turned “ON”. The pump will restart once the start button is pushed and continue when the engine starts. To purge the system of air if fuel lines have been removed, the ignition switch can be toggled “ON” and “OFF” (at 3 second intervals) until fuel flows through the fuel return line in the neck of the fuel line.

PIPELINER® 200G

DDD-4 DDD-4

I

EVERY 600 HOURS OR 12 MONTHS

E

VERY 200 HOURS OR 6 MONTHS

EVERY 100 HOURS OR 3 MONTHS

FIRST SERVICE-(50 HOURS)

E

VERY DAY OR EVERY 8 HOURS

If necessary use shorter periods.

These preventive maintenance periods apply to average conditions of operation.

PSI #32500292

AC PF25

T

YPE OR QUANTITY

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

4.5qrts, (4.3L) (including filter)

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

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

9.9qrts, (9.4L)

(1) Consult Engine Operators Manual for oil recommendations.

(4) Clean the air filter if the engine is operating in very dusty conditions.

NOTES:

Alternator belt Good Year 11AV0955 Fan belt Good Year 11AV1220

Alternator / fan belt wear

R

Tension of alternator / Fan belt

I

Drain fuel bowl

Engine oil (NOTE 1 & 3)

R

Engine oil level (NOTE 1)

Coolant (NOTE 3)

M

AINTENANCE ITEM

Concentration of antifreeze

50 / 50 water glycol mixture

Radiator for contamination or blockage

C

I

R

C

oolant level

R

C

R

I

R

ENGINE SERVICE

I

Fuel filter canister

S20919-3

BCI GROUP 45

Donaldson #P181050 or Nelson #70206N

4 - AC R46TS

R = ReplaceC = Clean

Battery

Leaks or engine damage

I

Air filter element

All nuts and bolts for tightness

I = Inspect

Electrical systems

R

4CC

Spark Plugs (Gap = 0.040")

I

Tighten cylinder head

I

R

Air filter (earlier check may be req'd.)

R

I

Engine oil filter

E

NGINE SERVICE (NOTE 2)

MAINTENANCE

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PIPELINER® 200G

DDD-5 DDD-5

9

8

1

5

2

7

9

4

6

3

6

MAINTENANCE

1. Case Front Assembly

2. Engine Assembly

3. Exciter Frame, Armature Assembly

4. Generator Frame, Armature & Coupling

5. Fuel Tank Assembly

6. Generator & Exciter Brush Holder Assemblies

7. Base & Lift Bale Assembly

8. Radiator Assembly

9. Roof & Doors

Figure DDD.1 - Major Component Location

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PIPELINER® 200G

DDD-6 DDD-6

NOTES

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PIPELINER® 200G

E-1 E-1

NEGATIVE OUTPUT TERMINAL

SWITCH

-

SELECTOR

90 Min.

Max

GENERATOR

ARMATURE

BRUSHES

&

COMMUTATOR

ENGINE IDLER SOLENOID

INTERPOLE

COILS

RESIDUAL

MAGNETISM

GENERATOR

FIELD CONTROL

SHUNT FIELD

SERIES F

IELD

ARMATURE

E

XCITER

DC

ARMATURE

SHAFT

_

+

S

ERIES

C

OILS

TO

ENGINE

CONTROL/PROTECTION

M

ODULE

POSITIVE OUTPUT TERMINAL

+

SHUNT FIELD COILS

1

5AMP FUSE

R

ECEPTACLE

120VDC

MECHANICAL

C

OUPLING

12VOLT BATTERY

ENGINE

PERKINS DIESEL

FROM CURRENT SENSING P.C.BOARD

I

DLER

S

WITCH

IDLER/ENGINE

PROTECTION

P

.C. BOARD

ENGINE F

AILURE

LAMP

ENGINE H

OUR

METER

F

UEL

PUMP

FUEL

SOLENOID

O

IL

GAUGE

O

IL SENSOR SWITCH

TEMP.

S

ENSOR

SWITCH

T

EMP.

G

AUGE

S

TARTER MOTOR

ENGINE

A

LTERNATOR

GLOWPLUGS

TO

BATTERY

IGNITION

SWITCH

+

-

Current S

ensing

P

.C.Board

ENGINE

ALTERNATOR

12VOLT BATTERY

MAP

SENSOR

WATER

& AIRTEMP. SENSOR

OIL PRESSURE& WATERTEMP.

SENSOR

THROTTLE

PLATE

MOTOR

FUEL PUMP

FUEL

INJECTORS

FROMCURRENT SENSINGP.C.BOARD

I

DLER

SWITCH

ENGINE

FAILURE

LAMP

ENGINE HOUR METER

R

PM

C

ONTROL

E

NG.IGNITION

CIRCUITRY

STARTER MOTOR

ZENITH

THROTTLE

BODY

CONTROLLER

G.M.

GASOLINE

ENGINE

OIL

GAUGE

WATER GAUGE

ENGINE IGNITION SWITCH

COUPLEDTO

GENERATOR

ENGINE

ALTERNATOR

ENGINE SPEED SENSOR

ENGINE

SPEED

ACTUATOR

FROMCURRENT S

ENSINGP.C.BOARD

I

DLER

S

WITCH

ENGINE

P

ROTECTION

LAMP

ENGINE

HOUR

METER

RPM

CONTROL

STARTER MOTOR

ENGINE

CONTROL

UNIT (ECU)

KUBOTA

DIESEL

ENGINE

O

IL

GAUGE

GLOWPLUGS

OIL SENSOR SWITCH

TEMP. SENSOR SWITCH

TEMP. GAUGE

START RELAY

ENGINE IGNITION SWITCH

COUPLEDTO

GENERATOR

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3/5

Generator & Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6

DC Generator Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7

FIGURE E.1 — BLOCK LOGIC DIAGRAM

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PIPELINER® 200

E-2 E-2

NEGATIVE OUTPUT T

ERMINAL

SWITCH

-

SELECTOR

90 Min.

Max

GENERATOR

ARMATURE

BRUSHES

&

COMMUTATOR

ENGINE IDLER S

OLENOID

INTERPOLE

COILS

RESIDUAL

MAGNETISM

G

ENERATOR

FIELD CONTROL

S

HUNT

FIELD

SERIES F

IELD

ARMATURE

EXCITER

D

C

ARMATURE

SHAFT

_

+

SERIES COILS

TO

ENGINE

CONTROL/PROTECTION

MODULE

POSITIVE OUTPUT TERMINAL

+

S

HUNT FIELD COILS

15AMP

FUSE

R

ECEPTACLE

120VDC

M

ECHANICAL COUPLING

1

2VOLT

BATTERY

ENGINE

P

ERKINS DIESEL

FROM CURRENT SENSING P.C.BOARD

I

DLER

SWITCH

IDLER/ENGINE

P

ROTECTION

P.C.BOARD

ENGINE FAILURE L

AMP

E

NGINE

H

OUR

METER

F

UEL

PUMP

FUEL

SOLENOID

O

IL

GAUGE

OIL

S

ENSOR

SWITCH

TEMP. SENSOR S

WITCH

TEMP.

GAUGE

S

TARTER MOTOR

ENGINE

ALTERNATOR

GLOWPLUGS

TO

BATTERY

IGNITION

SWITCH

+

-

C

urrent Sensing P.C.Board

ENGINE

ALTERNATOR

12VOLT BATTERY

MAP

S

ENSOR

WATER

& AIRTEMP. SENSOR

OIL PRESSURE& WATERTEMP.

SENSOR

THROTTLE

PLATE

MOTOR

FUEL PUMP

FUEL

INJECTORS

FROMCURRENT SENSINGP.C.BOARD

IDLER

SWITCH

ENGINE

FAILURE

LAMP

ENGINE HOUR METER

RPM

C

ONTROL

ENG.IGNITION

CIRCUITRY

STARTER MOTOR

ZENITH

THROTTLE

BODY

CONTROLLER

G.M.

GASOLINE

ENGINE

O

IL

GAUGE

WATER GAUGE

ENGINE IGNITION SWITCH

COUPLEDTO

GENERATOR

ENGINE

ALTERNATOR

E

NGINE

S

PEED

S

ENSOR

ENGINE

SPEED

ACTUATOR

FROMCURRENT SENSINGP.C.BOARD

IDLER S

WITCH

ENGINE

PROTECTION

L

AMP

ENGINE

HOUR

METER

RPM

CONTROL

STARTER MOTOR

E

NGINE

C

ONTROL

U

NIT

(

ECU)

KUBOTA

DIESEL

E

NGINE

OIL

GAUGE

GLOWPLUGS

OIL

S

ENSOR

S

WITCH

TEMP. SENSOR SWITCH

TEMP. GAUGE

START RELAY

ENGINE IGNITION SWITCH

C

OUPLED TO

GENERATOR

THEORY OF OPERATION

FIGURE E.2 — GENERAL DESCRIPTION

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GENERAL DESCRIPTION

The PIPELINER® 200 is a heavy duty, engine driven, DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding. Also, a total of 1750 watts of auxiliary power is available at the 120VDC receptacle. The PIPELINER® 200 is manufactured with all copper windings.

PIPELINER® 200

E-3 E-3

ENGINE

ALTERNATOR

ENGINE SPEED SENSOR

E

NGINE

S

PEED

ACTUATOR

FROM CURRENT SENSING P.C.BOARD

I

DLER

SWITCH

ENGINE

PROTECTION

LAMP

ENGINE HOUR METER

RPM

CONTROL

STARTER M

OTOR

ENGINE

CONTROL

U

NIT

(ECU)

KUBOTA

DIESEL

ENGINE

OIL

GAUGE

G

LOWPLUGS

OIL SENSOR S

WITCH

TEMP. SENSOR SWITCH

T

EMP.

GAUGE

START R

ELAY

E

NGINE

I

GNITION

SWITCH

COUPLED TO

GENERATOR

THEORY OF OPERATION

FIGURE E.3 — ENGINE CONTROL

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BATTERY, STARTER, ENGINE ALTERNATOR, OIL, & TEMPERATURE SWITCH CIRCUITS

The 12VDC battery powers the starter motor and, through the ignition switch, the engine ignition circuitry (gas models only), the engine alternator, the engine control protection modules and associated circuits. See the appropriate block diagram. These engine control and protection modules monitor engine oil pressure, coolant temperature and engine RPM. The system shuts the engine down in the event of a sudden low oil pressure or high coolant temperature. A warning light on the control panel provides fault codes, or on some models the engine fault light will glow.

The engine idle control (solenoid, throttle plates or actuator) is mechanically connected to the engine. When welding current or auxiliary power (120VDC) is drawn through the current sensing P.C. board a small voltage signal is sent to the engine control circuitry. This signals the engine control circuitry to increase the engine RPM. This is accomplished in a variety of methods depending upon the engine and control/protection being used.

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When the welding or auxiliary load is removed a preset time delay of about 15 seconds starts. After approximately 15 seconds of “no load” the engine control/protection circuitry returns the engine to low idle RPM.

PIPELINER® 200

E-4 E-4

ENGINE IDLER SOLENOID

12 VOLT BATTERY

ENGINE

PERKINS DIESEL

F

ROM CURRENT

SENSING P.C. BOARD

IDLER

SWITCH

IDLER/ENGINE

PROTECTION

P.C. BOARD

ENGINE FAILURE

LAMP

ENGINE

HOUR

M

ETER

F

UEL

PUMP

FUEL

SOLENOID

O

IL

GAUGE

OIL SENSOR SWITCH

TEMP.

S

ENSOR

S

WITCH

TEMP.

GAUGE

STARTER MOTOR

E

NGINE

A

LTERNATOR

GLOWPLUGS

TO

BATTERY

IGNITION

S

WITCH

COUPLED TO

GENERATOR

THEORY OF OPERATION

FIGURE E.4 — ENGINE CONTROL

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BATTERY, STARTER, ENGINE ALTERNATOR, OIL, & TEMPERATURE SWITCH CIRCUITS

The 12VDC battery powers the starter motor and, through the ignition switch, the engine ignition circuitry (gas models only), the engine alternator, the engine control protection modules and associated circuits. See the appropriate block diagram. These engine control and protection modules monitor engine oil pressure, coolant temperature and engine RPM. The system shuts the engine down in the event of a sudden low oil pressure or high coolant temperature. A warning light on the control panel provides fault codes, or on some models the engine fault light will glow.

The engine idle control (solenoid, throttle plates or actuator) is mechanically connected to the engine. When welding current or auxiliary power (120VDC) is drawn through the current sensing P.C. board a small voltage signal is sent to the engine control circuitry. This signals the engine control circuitry to increase the engine RPM. This is accomplished in a variety of methods depending upon the engine and control/protection being used.

When the welding or auxiliary load is removed a preset time delay of about 15 seconds starts. After approximately 15 seconds of “no load” the engine control/protection circuitry returns the engine to low idle RPM.

PIPELINER® 200

E-5 E-5

E

NGINE

ALTERNATOR

12 VOLT B

ATTERY

MAP

SENSOR

WATER

&

A

IR TEMP.

SENSOR

O

IL

P

RESSURE &

WATERTEMP.

SENSOR

THROTTLE

PLATE

MOTOR

FUEL

PUMP

FUEL

INJECTORS

FROM CURRENT SENSING P.C.BOARD

I

DLER

S

WITCH

E

NGINE

FAILURE

L

AMP

ENGINE

HOUR

METER

RPM

C

ONTROL

ENG.IGNITION

C

IRCUITRY

STARTER MOTOR

ZENITH

THROTTLE

BODY

C

ONTROLLER

G

.M.

GASOLINE

ENGINE

O

IL

GAUGE

WATER GAUGE

ENGINE

IGNITION

S

WITCH

COUPLED TO

G

ENERATOR

THEORY OF OPERATION

FIGURE E.5 — ENGINE CONTROL

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BATTERY, STARTER, ENGINE ALTERNATOR, OIL, & TEMPERATURE SWITCH CIRCUITS

The 12VDC battery powers the starter motor and, through the ignition switch, the engine ignition circuitry (gas models only), the engine alternator, the engine control protection modules and associated circuits. See the appropriate block diagram. These engine control and protection modules monitor engine oil pressure, coolant temperature and engine RPM. The system shuts the engine down in the event of a sudden low oil pressure or high coolant temperature. A warning light on the control panel provides fault codes, or on some models the engine fault light will glow.

The engine idle control (solenoid, throttle plates or actuator) is mechanically connected to the engine. When welding current or auxiliary power (120VDC) is drawn through the current sensing P.C. board a small voltage signal is sent to the engine control circuitry. This signals the engine control circuitry to increase the engine RPM. This is accomplished in a variety of methods depending upon the engine and control/protection being used.

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When the welding or auxiliary load is removed a preset time delay of about 15 seconds starts. After approximately 15 seconds of “no load” the engine control/protection circuitry returns the engine to low idle RPM.

PIPELINER® 200

E-6 E-6

N

EGATIVE OUTPUT TERMINAL

S

WITCH

-

S

ELECTOR

9

0 Min.

Max

GENERATOR

ARMATURE

BRUSHES

&

COMMUTATOR

INTERPOLE

C

OILS

RESIDUAL

MAGNETISM

GENERATOR

FIELD CONTROL

SHUNT

FIELD

S

ERIES

FIELD

ARMATURE

E

XCITER

DC

A

RMATURE

SHAFT

_

+

SERIES

C

OILS

TO

ENGINE

CONTROL/PROTECTION

MODULE

P

OSITIVE OUTPUT TERMINAL

+

SHUNT FIELD COILS

1

5 AMP FUSE

RECEPTACLE 120VDC

MECHANICAL

COUPLING

+

-

Current Sensing P.C.Board

THEORY OF OPERATION

FIGURE E.6 — GENERATOR & EXCITER

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ENGINE, MAIN GENERATOR ARMATURE & FRAME AND DC EXCITER

EXCITATION (FLASHING)

The main generator armature and the exciter armature are mechanically coupled to the engine. When the engine is started and running, the residual magnetism that is stored in the exciter pole pieces is induced upon the exciter armature. This causes the exciter to “buildup” and produce a DC output voltage. This DC is applied, via the field rheostat control, to the main generator shunt field coils. The exciter output is also connected to the 120VDC receptacle.

MAIN SHUNT, INTERPOLE & SERIES COILS

The generator armature rotates within the magnetic field created by the shunt field windings. A DC voltage is induced in the armature and is transferred, through the armature commutator and brushes, to the series and interpole coils. The interpole coils, which are connected in series with the positive output terminal, are located so as to counteract any magnetic influences that could cause mechanical distortion in the rotating armature. The series coils are designed to oppose or “buck” the DC voltage that is generated in the armature.

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PIPELINER® 200

ENGINE, MAIN GENERATOR ARMATURE, FRAME & DC EXCITER

CURRENT RANGE SELECTOR

The selector switch acts as a course current adjustment by allowing varying amounts of series windings to be included in the welding current path. The series coils and selector switch are connected in series with the negative output terminal.

FINE CURRENT ADJUSTMENT

The field rheostat control functions as a fine output current adjustment by controlling the current through the shunt windings, thus controlling the amount of magnetism created in the field windings. Open circuit weld voltage can also be controlled by the field rheostat control.

E-7 E-7

BRUSH

MAGNETIC FIELD

G

ENERATOR

ARMATURE

MAGNETIC FIELD

SHUNT FIELD WINDINGS

M

ECHANICAL

COUPLING

ARMATURE

SHAFT

DC CURRENT

F

I E L D

C U R R E N T

F

I E L D

C U R R E N T

THEORY OF OPERATION

FIGURE E.7 — DC GENERATOR THEORY

DC GENERATOR MACHINES

The armature winding of a DC generator is located on the rotating member. Current is conducted from it by means of carbon brushes. The field winding is located in the stator, which is stationary and excited by direct current.

The armature coil sides are placed at opposite points on the rotating shaft with the conductors parallel to the shaft. The armature assembly is normally turned at a constant speed by a source of mechanical power connected to the shaft. When the armature rotates through the magnetic field produced by the stationary field winding, it induces a coil voltage in the armature winding. The voltage induced in an individual armature coil is an alternating (AC) voltage, which must be rectified. In a conventional DC generator machine, rectification is provided mechanically by means of a commutator. A commutator is a cylinder formed of copper segments insulated from each other and mounted on, but insulated from, the rotating shaft. Stationary carbon brushes held against the commutator surface connect the armature windings to external terminals. The commutator provides full-wave rectification, transforming the voltage waveform between brushes and making available a DC voltage to the external circuit.

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PIPELINER® 200

E-8 E-8

NOTES

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PIPELINER® 200

F-1 F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

DC Exciter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Idler Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17

Main Generator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19

Flashing The Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23

Engine Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27

Oil Pressure - Temp. Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Current Sensor PCB Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

Engine Throttle Adjustment Test (Perkins Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37

Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41/43

Removal & Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45

DC Armature & Field Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45

Main Generator Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49

Main Generator Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-61

Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-63

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PIPELINER® 200

F-2 F-2

TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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

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

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

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: output problems and welding problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED

COURSE OF ACTION

The last column labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the specified test points, components, terminal strips, etc. can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

to eliminate

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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

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PIPELINER® 200

F-3 F-3

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK can kill.

•

Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touc h electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assur e that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC board can be damaged by static electricity.

- R e m o v e y o u r b o dyʼs static charge before opening the staticshielding bag. Wear an anti-static wrist st rap. For s afety, use a 1 Meg ohm resistive cord connected

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

to a groun d e d part of th e equipment frame.

- If you donʼt have a wrist strap, touch an un-pain ted, grounded, part of the equipment frame. Keep touching t h e f r a m e to pr event static build-up. Be su r e n o t t o touch any electrically live parts at the same time.

- Remove the PC board from the static-shielding bag and place it directly into the equipment. Donʼt set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board canʼt be installed immediately, put it back in the static-shielding bag.

- If the PC board uses protective shorting jumpers, donʼt remove them until installation is complete.

- If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the failure

symptom has been co r r e c t e d by t h e replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical compo nents can r each th eir operating temperature.

5. Remov e t h e r e p l a c e m ent PC board and

substitute it with the original PC board to recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC board was not the problem. Continue to look fo r bad connections in th e co ntrol wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC board w a s the problem. R einstall t h e replacement PC board and test the machine.

6. Alwa y s indicate th a t this procedure wa s

followed when w a r r a n t y reports are t o b e submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

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PIPELINER® 200

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The engine starts and runs at correct speed, but there is no, or very low, welder output voltage. There is no DC auxiliary output voltage.

The engine starts and runs at the correct speed but there is no, or very low, welder output. The DC auxiliary output voltage is normal.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check for loose or missing brushes in the DC exciter.

2. The exciter may need “flashing.” See Flashing the Fields in this section.

1. Check the welding cables for loose or faulty connections.

2. Check for loose or missing brushes in the welding generator.

3. Check for open circuit voltage at weld studs, check heavy current carrying leads for loose or corroded connections

RECOMMENDED

COURSE OF ACTION

1. Check for loose or broken wires between the exciter brushes and the DC receptacle and the fine current control field rheostat. See the Wiring Diagram.

2. Perform the DC Exciter Test.

1. Check the fine current control field rheostat for resistance and proper operation. Normal resistance is 64 ohms. Check associated wires for loose or faulty connections. See the Wiring Diagram.

2. Perform the Main Generator Shunt Field Winding Test.

3. Check the continuity of the interpole coils. They should show continuity from the positive brusholders to the positive output terminal and should NOT be grounded to the generator frame.

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4. Check the continuity of the series coils. They should show continuity from the negative brusholders, through the current selector switch, to the negative output terminal and should NOT be grounded to the generator frame.

5. The main armature may be faulty. Check for grounds and/or shorts.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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PIPELINER® 200

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The welding output varies abnormally. The auxiliary output remains constant. The engine is operating correctly.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check for loose or faulty welding cables.

2. This may be a normal condition. The machine will normally lose some output as the components are heated.

3. Check for loose, worn, dirty or poorly seated main DC generator brushes.

4. The main armature commutator may need cleaning.

RECOMMENDED

COURSE OF ACTION

1. Check the fine current control field rheostat for resistance and proper operation. Normal resistance is 64 ohms. Check associated wires for loose or faulty connections. See the Wiring Diagram.

2. Perform the Main Generator

Shunt Field Winding Test.

3. Check the current range selector switch and contacts for proper operation.

4. While the machine is loaded, check the interpole and series coils for signs of “arcing.” This condition would indicate shorted turns in the “arcing” coil.

The engine starts and runs at the correct speed, but there is no DC auxiliary output voltage at the 115VDC receptacle. The welding generator is functioning correctly.

1. Check the DC receptacle and plug for loose or faulty connections.

2. Check the 15 Amp fuse. (Not on GM 3.0L gas)

5. The main armature may be faulty. Check for grounds.

1. Check for loose or faulty connections or wires at the 120 VDC receptacle and associated circuitry. See the Wiring Diagram.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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PIPELINER® 200

F-6 F-6

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The actual welding current is much less than is indicated on the dials.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check the welding cables for loose or faulty connections.

2. The welding cables may be excessively long or coiled.

3. Check the main DC generator brushes for good commutation and alignment. Contact the

Lincoln Electric Service Dept. 1-

888-935-3877.

RECOMMENDED

COURSE OF ACTION

1. The engine RPM may be low. If necessary perform the

Engine Throttle Adjustment Test. (PERKINS code 10929 ONLY)

2. Perform the DC Exciter Test.

3. Check the fine current control field rheostat for resistance and proper operation. Normal resistance is 64 ohms. Check associated wires for loose or faulty connections. See the Wiring Diagram.

4. Check the current range selector switch and contacts for proper operation.

5. Perform the Main Generator

Shunt Field Winding Test.

The actual welding current is much greater than is indicated on the dials.

1. Check the main DC generator brushes for good commutation and alignment. Contact the Lincoln Electric Service Dept. 1-888-935-3877.

6. The main armature may be faulty. Check for grounds.

1. The engine operating speed may be too high. If necessary perform the Engine Throttle

Adjustment Test. (PERKINS code 10929 ONLY)

2. While the machine is loaded, check the series coils for signs of “arcing.” This condition could point to shorted turns in the series coils.

3. Perform the DC Exciter Test.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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PIPELINER® 200

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The engine will not return to low idle when the welding and auxiliary loads are removed.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure the idler control switch is set to the “Auto” position.

2. Make sure both welding and auxiliary loads are removed.

3. Check for mechanical restrictions in the idler and throttle linkage (PERKINS code 10929 ONLY) There may be a problem with the ECU or Throttle Body Controller or associated engine control components on Kubota Diesel (1114, 11316) and GM Gas(10660, 10913,

11136)Contact the Lincoln Electric Service Dept. 1-888935-3877.

RECOMMENDED

COURSE OF ACTION

1. Check the idler control switch and associated leads for loose or faulty connections. See the Wiring Diagram.

2. Check the CURRENT SENSING PC BOARD

Perform the Current Sense Board Test. Replace if

necessary.

3. Perform the Idler Solenoid

Test. (PERKINS 10929 ONLY)

4. Check for loose or faulty connections at the idler PC board (PERKINS) ECU in Kubota and Throttle Body Controller GM 3.0 liter.

5. The idler PC board (PERKINS) ECU in Kubota or Throttle Body Controller -GM

3.0 liter may be faulty. Contact the Lincoln Electric Service Dept. 1-888-935-

3877.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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PIPELINER® 200

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The engine will NOT go to high speed when a load is applied to the welding output terminals. The engine does go to high speed when a load is applied to the DC auxiliary power receptacle. When the engine is operating in the high RPM condition, both welding output and DC auxiliary are normal.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check welding cables for loose or faulty connections.

RECOMMENDED

COURSE OF ACTION

1. Check the idler control switch and associated leads for loose or faulty connections. See the Wiring Diagram.

2. Check the CURRENT SENSING PC BOARD.

Perform the Current Sense Board Test. Replace if

necessary.

3. Perform the Idler Solenoid

Test. (PERKINS 10929 ONLY)

4. Check for loose or faulty connections at the idler PC board (PERKINS) ECU in Kubota and Throttle Body Controller GM 3.0 liter.

5. The idler PC board (PERKINS) ECU in Kubota or Throttle Body Controller -GM

3.0 liter may be faulty. Contact the Lincoln Electric Service Dept. 1-888-935-

3877.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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PIPELINER® 200

F-9 F-9

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The engine will NOT go to high speed when a load is applied to the DC auxiliary receptacle. The engine does go to high speed when a load is applied to the welding output terminals. When the engine is operating in the high RPM condition, both welding output and DC auxiliary are normal.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check the auxiliary power plug and associated leads for loose or faulty connections.

2. The load may be too small. The load must be above 150 watts.

RECOMMENDED

COURSE OF ACTION

1. Check the idler control switch and associated leads for loose or faulty connections. See the Wiring Diagram.

2. Check the CURRENT SENSING PC BOARD.

Perform the Current Sense Board Test. Replace if

necessary.

3. Perform the Idler Solenoid

Test. (PERKINS 10929 ONLY)

4. Check for loose or faulty connections at the idler PC board (PERKINS) ECU in Kubota and Throttle Body Controller GM 3.0 liter.

5. The idler PC board (PERKINS) ECU in Kubota or Throttle Body Controller -GM

3.0 liter may be faulty. Contact the Lincoln Electric Service Dept. 1-888-935-

3877.

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The engine “cranks” but will not start.

1. Make sure the ignition switch is in the ON position.

2. Check for adequate fuel supply.

1. Check the ignition switch for proper operation. Check the associated leads for loose or faulty connections. See the Wiring Diagram.

2. Check the fuel solenoid. Make sure it is opening when +12VDC is applied.(Except Kubota) See the Wiring Diagram.

3. The idler PC board may be faulty (Perkins 10929) Replace, OR The ECU Kubota or Throttle Body Controller GM

3.0 Liter may be faulty. Contact the Lincoln Electric Service Dept. 1-888-935-3877.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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PIPELINER® 200

F-10 F-10

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The engine “cranks” AND starts, but runs only about 30-60 seconds and shuts down.

The welding arc is loud and spatters excessively.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELDING PROBLEMS

1. Make sure the correct grade and amount of oil is in the engine crankcase. See the Maintenance Section of this manual.

2. Make sure the engine is not overheating.

3. Make sure the engine alternator is operating properly.

1. The current setting may be too

high for the electrode and process.

2. The polarity may be wrong for the electrode and process.

RECOMMENDED

COURSE OF ACTION

1. The oil pressure switch may

be faulty. Perform the Oil

Pressure Switch Test.

2. The Temperature Switch may be fault. Perform the

Temperature Switch Test.

3. The alternator may be faulty. Perform the Alternator Test.

4. The Idler/Engine Protection Board may be faulty (PERKINS) The ECU (KUBO11:29 AMA) or Throttle Body Controller (GM 3.0 Liter) may be faulty. Contact the Lincoln Electric Service Dept. 1-888-935-3877.

1. Check the engine speed. High idle speed should be 1800 RPM. If Necessary, perform the Engine Throttle

Adjustment Test. (PERKINS ONLY 10929)

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2. Check the main DC generator brushes for good commutation and alignment. Contact the Lincoln Electric Service Dept. at 1-888-935-3877.

The welding arc frequently “pops out”.

1. The fine current control field rheostat may be set too low for the process and electrode.

2. Check the welding cables for loose or faulty connections.

1. Check the engine speed. High idle speed should be 1800 RPM. If Necessary, perform the

Engine Throttle Adjustment Test. (PERKINS ONLY 10929)

2. The Current Range Selector Switch may be faulty. Check for proper operation and contact.

3. Check the DC generator brushes for good commutation and alignment. Contact the Lincoln Electric Service Dept. at 1-888-935-3877.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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PIPELINER® 200

F-11 F-11

TROUBLESHOOTING & REPAIR

Observe all Safety Guidelines detailed throughout this manual

Kubota - EUC - Codes

LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE

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

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

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PIPELINER® 200

F-12 F-12

NOTES

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PIPELINER® 200

F-13 F-13

TROUBLESHOOTING & REPAIR

DC EXCITER TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine whether or not the DC exciter is operating correctly. If operation is not correct , the test will also determine what component(s) may be faulty.

MATERIALS NEEDED

3/8" wrench Volt/Ohmmeter (Multimeter) Wiring Diagram

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PIPELINER® 200

F-14 F-14

SERIES COIL CONNECTION POINT (NEGATIVE)

POSITIVE

TROUBLESHOOTING & REPAIR

DC EXCITER TEST (CONTINUED)

FIGURE F.1 – 120VDC RECEPTACLE

TEST PROCEDURE

1. Turn off the engine and remove all external loads to the welder terminals and auxiliary receptacle.

WARNING

MOVING PARTS can injure.

• Remove guards only when necessary to perform service, and replace them when the service requiring their removal is complete.

• Keep hands, hair, clothing and tools away from Vbelts, gears, fans, and all other moving parts when starting, operating, or repairing equipment.

• If fan guards are missing from a machine, obtain replacements from a Lincoln Distributor. (See Parts List.) Always use greatest care when working near moving parts.

2. Start the engine and put the idler switch in the HIGH idle position.

3. Using the volt/ohmmeter, carefully check the DC voltage at the 120V receptacle. (Observe proper polarity. The large slot of the receptacle is negative. See Figure F.1.) Normal voltage is 125 - 135VDC, no load, with the engine at the high idle speed of 1600 RPM. If the voltage is normal, the DC exciter is functioning correctly. If the voltage is low or not present, proceed to the next step.

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PIPELINER® 200

F-15 F-15

EXITER COVER

W

ARRANTY

CHECK VOLTAGE AT BRUSH HOLDERS HERE (RIGHT SIDE IS +)

+

TROUBLESHOOTING & REPAIR

DC EXCITER TEST (CONTINUED)

FIGURE F.2 – EXCITER COVER REMOVAL

4. Turn off the engine. Using the 3/8” nut driver, remove the exciter cover. See Figure F.2.

5. Start the engine. Using the volt/ohmmeter, carefully check the DC voltage at the brush holders. See Figure F.2. The right side brush holder is positive polarity. Normal DC voltage is 125 - 135VDC with the engine at the high idle speed of 1600 RPM.

6. If the DC voltage is normal at the brush holders, the DC exciter armature and shunt coils are OK.

a. If the voltage is low or not present, proceed with

the shunt coil and series coil resistance tests.

b. If the correct DC voltage is present at the brush

holders but not at the 120VDC receptacle, the series coil or associated leads may be faulty. See the Wiring Diagram. Proceed with the shunt coil and series coil resistance tests.

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PIPELINER® 200

F-16 F-16

WHITE FLEX LEAD

SMALL FLEX LEAD

SOLID LEAD

WARRANTY

EXCITER SHUNT FIELD

EXCITER

ARMATURE

EXCITER SERIES FIELD

120 VOLTS

D

C

#2

#

1

TTTT

T

TT

12

11 1

2

43

13

1

4

-

+

RED LEAD -

TROUBLESHOOTING & REPAIR

DC EXCITER TEST (continued)

FIGURE F.3 – BRUSH HOLDER LEADS

SHUNT COIL AND SERIES COIL RESISTANCE TESTS

Note: Two coils make up a set (L8707), and each coil

10. The coil leads should be disconnected from the

11. Using the Ohmmeter, measure the Exciter Series

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7. Turn the engine OFF.

8. Using the 3/8" nut driver, disconnect the two leads from the left side brush holder. See Figure F.3. Separate the two leads. One will be a larger "solid" lead (series coil). The other will be a smaller flex lead (shunt coil).

9. Using the 3/8" nut driver, remove the two flex leads from the right side brush holder.

consists of two coils, wound together. An Exciter Shunt Field Coil and an Exciter Series Coil.

positive and negative brush holder and also the bolted connection within the exciter bracket that connects T12 to the RED lead.

Coils from the T12 and T2 (heavy stiff magnet wire) and the Exciter Shunt Field Coils from T4 and T14 (fine stranded wire) to a good frame ground. The resistance should be very high (500k Ohms or higher). This indicates that the coils are not grounded. If the resistance reading is less than 500k Ohms, this indicates a grounded condition and replacement should be considered.

PIPELINER® 200

12. Using the Ohmmeter, measure Exciter Series Field Coils from connection T12 to connection T2. The resistance should be .276 to .296 Ohms. Measure with the Ohmmeter the Exciter Shunt Field Coils between T4 and T14, The resistance should be 127.0 to 133.0 Ohms. If resistance is very low, the coils are shorted. If coils are warmer or colder than 25 degrees Celsius, the resistance will be considerably higher or lower. If coil resistances vary significantly, REPLACEMENT MAY BE NECESSARY.

13. If the shunt and series coils are good, and the exciter is not operating properly, the exciter armature may be faulty. Replace the exciter armature.

14. After the test and repairs are completed, install the exciter cover using the 3/8” nut driver.

F-17 F-17

TROUBLESHOOTING & REPAIR

IDLER SOLENOID TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine whether or not the idler solenoid can function when it is energized with 12VDC.

MATERIALS NEEDED

External 12VDC supply Wiring Diagram Volt/ohmmeter (Multimeter)

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PIPELINER® 200

F-18 F-18

QUICK CONNECT LEADS

TROUBLESHOOTING & REPAIR

IDLER SOLENOID TEST (continued)

FIGURE F.4 – IDLER SOLENOID CONNECTIONS

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TEST PROCEDURE

1. Turn the engine OFF.

2. Unlatch and secure the right side door.

3. Locate the idler solenoid and the two leads with quick connects. See Figure F.4.

4. Disconnect the two solenoid leads at the quick connection splices.

5. Using the external power supply, apply 12VDC to the idler solenoid leads. The solenoid should activate.

6. The solenoid should deactivate when the 12VDC is removed.

PIPELINER® 200

7. If the solenoid does not operate properly, check for a mechanical restriction in the linkage or for a missing spring.

8. If the linkage is intact and the solenoid does not operate correctly when 12VDC is applied, the idler solenoid may be faulty. Replace the idler solenoid.

NOTE: Normal solenoid coil resistance is approxi-

mately 9 ohms.

9. After the test and repairs are completed, close and

latch the right side door.

F-19 F-19

TROUBLESHOOTING & REPAIR

MAIN GENERATOR SHUNT FIELD WINDING TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine whether or not the main shunt field coils are shorted, open, or grounded.

MATERIALS NEEDED

Volt/ohmmeter (Multimeter) Wiring Diagram

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PIPELINER® 200

F-20 F-20

PLUG P10

TROUBLESHOOTING & REPAIR

MAIN GENERATOR SHUNT FIELD WINDING TEST (continued)

FIGURE F.5 – PLUG P10 LOCATION

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TEST PROCEDURE

1. Turn the engine OFF.

2. Unlatch, lift and secure the right side door.

3. Locate plug P10. See Figure F.5.

4. Remove plug P10.

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PIPELINER® 200

F-21 F-21

PIN 3

PIN 5

TAB

TROUBLESHOOTING & REPAIR

MAIN GENERATOR SHUNT FIELD WINDING TEST (continued)

FIGURE F.6 – PLUG P10 PIN ASSIGNMENTS

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5. Locate the blue (U) (pin 3) and the brown (N) (pin 5) leads in the harness plug. See Figure F.6.

6. Using the volt/ohmmeter, measure the resistance between the blue and the brown lead. Normal resistance is approximately 40 ohms.

7. Also measure the resistance from either lead (blue or brown) to ground. This resistance should be at least 500,000 ohms.

8. If the test does not meet the resistance specifications, then check the harness plug for loose connections or shorted leads.

PIPELINER® 200

9. If the plug and associated leads are okay, the shunt field coils may be faulty. Replace the shunt field coils.

10. If the test does meet the resistance specifications, the main shunt coils are okay.

11. Replace plug P10, making sure the leads

and plug are secure.

12. After the test and repairs are completed, close and latch the right side door.

F-22 F-22

NOTES

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PIPELINER® 200

F-23 F-23

TROUBLESHOOTING & REPAIR

FLASHING THE FIELDS

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will magnetize the exciter pole pieces. The exciter can then “build-up” when the engine is started.

MATERIALS NEEDED

12-volt battery Two jumper wires with alligator clips on each end Wiring Diagram 3/8” Nutdriver

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PIPELINER® 200

F-24 F-24

EXITER COVER

TROUBLESHOOTING & REPAIR

FLASHING THE FIELDS (continued)

FIGURE F.7 – EXCITER COVER REMOVAL

PROCEDURE

1. Turn the engine OFF.

2. Using a 3/8” Nutdriver, remove the exciter cover. See Figure F.7.

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PIPELINER® 200

F-25 F-25

+

RAISE EXCITER BRUSH OFF COMMUTATOR

TO POSITIVE BATTERY TERMINAL

TO NEGATIVE BATTERY TERMINAL

WARRANTY

TROUBLESHOOTING & REPAIR

FLASHING THE FIELDS (continued)

FIGURE F.8 - BRUSH HOLDER/BATTERY JUMPER CONNECTIONS

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3. Raise one exciter brush off the armature commutator.

4. Using the jumper leads and the 12VDC battery, first attach the clip of one lead to the POSITIVE terminal of the battery. Attach the other end of this same lead to the right side brush holder. See Figure F.8.

5. Carefully attach one clip of the other lead to the NEGATIVE terminal of the battery. Attach the other end of the same lead to the left side brush holder for approximately five seconds. Pull the lead away quickly to minimize arcing. See Figure F.8.

PIPELINER® 200

6. Remove both leads from the brush holders and the battery.

7. Install the brush removed in step 3.

8. Install the exciter cover using the 3/8” nut driver.

9. Start the engine. The exciter should produce DC output voltage.

F-26 F-26

NOTES

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PIPELINER® 200

F-27 F-27

TROUBLESHOOTING & REPAIR

ENGINE ALTERNATOR TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the engine alternator is properly charging the battery.

MATERIALS NEEDED

Miscellaneous Hand Tools Volt/Ohm Meter Wiring Diagram

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PIPELINER® 200

F-28 F-28

Alternator

Output

Leads

BACK OF ALTERNATOR

TROUBLESHOOTING & REPAIR

ENGINE ALTERNATOR TEST (CONTINUED)

FIGURE F.9 - ALTERNATOR LEAD LOCATIONS

TEST PROCEDURE

1. Turn the engine off.

2. Open the engine access door and check the voltage at the battery terminals. It should be approximately 12 volts DC.

3. Attach the meter leads to the battery terminals, being careful to position them so they stay clear of moving parts while the engine is running.

4. Place the idle switch in the “HIGH IDLE” position, start the engine, and allow it to run at high idle speed for about 15 to 30 seconds.

5. The meter should read about 13.7 to 14.2 VDC.

6. If the meter reads correctly the engine alternator is producing adequate power to charge the battery and this test is complete.

6. If the voltage is significantly higher than the above values, the alternator is not properly regulating the battery charging voltage and should be replaced. If the voltage reads the same or less than the measurement taken when the engine was not running, proceed with the following tests.

8. Make sure the idle switch is still in the “high” position, start the engine, and allow it to run at high idle speed for about 15 to 30 seconds.

9. Place the negative meter probe on a good chassis ground, or the negative battery terminal. Place the positive meter probe on the battery terminal on the back of the alternator. (Lead #51). See Wiring Diagram.

10. The meter should read about 13.7 to 14.2 VDC.

11. Move the positive probe to the DT terminal on the back of the alternator. See Wiring Diagram.

12. The meter should read about 13.7 to 14.2 VDC.

13. If the meter reads correctly, check the connections between the alternator and the battery. See wiring diagram.

14. If the voltage at both of the above test points reads the same or less than the battery voltage measurement taken when the engine was not running, the alternator is defective. Repair or replace it.

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7. Turn off the engine, disconnect the meter from the battery, and open the engine access door on the left side of the machine.

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PIPELINER® 200

F-29 F-29

TROUBLESHOOTING & REPAIR

OIL PRESSURE - TEMPERATURE SWITCH TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the Oil Pressure and/or Temperature Switch is functioning properly.

MATERIALS NEEDED

OhmMeter

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PIPELINER® 200

G

WK

OIL SWITCH / SENDER

S17026-3

TEMP SW. / SENDER

S25162

1

/2-14 NPT 1/4" SPADETERMINAL

3/16" SPADETERMINAL

G

W

G

ND

.19 .03

+

-

F-30 F-30

TROUBLESHOOTING & REPAIR

OIL PRESSURE - TEMPERATURE SWITCH TEST (CONTINUED)

FIGURE F.10 - SWITCH

WK TERMINAL TO GROUND TO CASE AT 6 +/-2 PSI. OTHERWISE TERMINAL TO BE OPEN

Oil Pressure Switch/Sender Resistance Test. S17026-3 (Kubota and Perkins Only)

PROCEDURE

1. With the engine not running locate the Oil Pressure Switch/Sender.

2. Remove the two leads from the switch.

3. Using the ohmmeter check the resistance from terminal WK to case ground. This is a normally closed switch and should be at a very low resistance. (Less than 1 ohm)

4. Using the ohmmeter check the resistance from terminal G to case ground. This resistance should be approximately 10 ohms with zero PSI oil pressure.

5. With the engine running and an oil pressure of 6 PSI or greater the resistance from terminal WK to case ground should be very high. (open). While the engine is running if the oil pressure should drop below 6 PSI the switch would close and shut off the engine.

6. With the engine running the resistance from terminal G to case ground should be as follows.

• 0 PSI equals approximately 10 ohms

• 40 PSI equals approximately 105 ohms

• 80 PSI equals approximately 187 ohms

8. Replace the two leads previously removed.

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PIPELINER® 200

Lincoln Electric PIPELINER 200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

The engine starts and runs at correct speed, but there is no, or very low, welder output voltage. There is no DC auxiliary output voltage.

The engine starts and runs at the correct speed but there is no, or very low, welder output. The DC auxiliary output voltage is normal.

The welding output varies abnormally. The auxiliary output remains constant. The engine is operating correctly.

The engine starts and runs at the correct speed, but there is no DC auxiliary output voltage at the 115VDC receptacle. The welding generator is functioning correctly.

The actual welding current is much less than is indicated on the dials.

The actual welding current is much greater than is indicated on the dials.

The engine will not return to low idle when the welding and auxiliary loads are removed.

The engine “cranks” but will not start.

The engine “cranks” AND starts, but runs only about 30-60 seconds and shuts down.

The welding arc is loud and spatters excessively.

The welding arc frequently “pops out”.