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
Copyright © Lincoln Global Inc.
• 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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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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
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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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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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
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