Lincoln_Electric_Welder

Safety Depends on You

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

NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT

WITHOUT READING THIS

MANUAL AND THE SAFETY

PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

??? World's Leader in Welding and Cutting Products ???

??? Sales and Service through Subsidiaries and Distributors Worldwide ???

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

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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

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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

PIPELINER?? 200D KUBOTA

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

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

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

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

PIPELINER?? 200D KUBOTA

a.When welding or drawing power for lights or tools (approximately 100 watts minimum) from the recep- tacles, the engine operates at high idle speed.

b.When welding ceases or the power load is turned off, a preset time delay of about 15 seconds starts. This time delay cannot be adjusted.

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

AUXILIARY POWER

1.75 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.

PIPELINER?? 200D KUBOTA

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

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

K953-1 Trailer

K958-1 Ball Hitch

K958-2 Lunette Eye Hitch

K959-1 Fender & Light Kit

K965-1 Cable Rack

K1858-1 AIR CLEANER SERVICE INDICATOR

STICK OPTIONS

K704 ACCESSORY SET - Includes 35 ft.(10 m) of electrode cable and 30 ft.(9 m) of work cable, head- shield, work clamp and electrode holder. Cable is rated at 500 amps, 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.

C-2

OPTIONAL FEATURES

GENERAL OPTIONS

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

Portable CV unit for InnershieldLN-23P WirepipeFeederwelding(K316L. Control-1)- cable operates con- tactor inside Wire Feed Module for ???cold??? electrode.

Requires LN-23P Adapter Kit (K350-1) and Gun and Cable Assembly.

Required to adapt LN- 23PLN-23Pto anyAdapterLincolnKitpower(K350source-1)- . Makes 14 pin con- nection at power source.

Magnum?? 250 Innershield Gun (for LN-23P) (

For lighter weight and easier handling. RatedK355-25010)- 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.

Portable CC/CV unit for fluxLN--25coredWireandFeederMIG welding(K449).-Includes Gas Solenoid & Internal Contactor. Requires Wire Feed Module.

K444-2)

ProvidesRemote 25Volft.age(7.5m)Controlof remoteKit outputfor LNvoltage-25 ( control and output jumper (2 and 4) for machines having 14 pin MS-type connector.

ForMagnum??self-shielded350 Innewireshieldwith Gun15 ft(for. (4.LN5m)-25)(K126cable. -For2)-

.062-3/32??? (1.6-2.8mm) wire. Magnum??15 ft. (4.5m)200cableMIG. ForGun.025(for(0.LN6m)-25)(wireK497. -3)-With

Connects Magnum200GunMIGCongunectorto LN-KiT25 Wire(K466Feeder-1) .

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

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

PIPELINER?? 200D KUBOTA

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

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

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

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

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

PIPELINER?? 200D KUBOTA

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.

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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

curved face to fit the commutator. Have an experi- enced 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 pres- sure air.

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

IDLER MAINTENANCE

Before doing electrical work, disconnect the bat- tery.

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

1. Proper operation of the idler requires good ground- ing of the Engine Control Unit, current sensing printed circuit board and battery.

2. If desired, the welder can be used without automat- 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 approx- imately 10 seconds).

3.Fully close the air bleeding valve by turning it clock- wise.

Contact your Kubota Engine repair facility if problems persist.

PIPELINER?? 200D KUBOTA

PIPELINER?? 200D PERKINS

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

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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.

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ENGINE EXHAUST can kill.

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

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MOVING PARTS can injure.

??? Do not operate with doors open or guards off.

??? Stop engine before servicing.

??? Keep away from moving parts.

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See additional warning information at front of this operator??s manual.

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EXHAUST SPARK ARRESTER

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

Use of an incorrect arrester may lead to engine dam- age or performance loss. Contact the engine manu- facturer for specific recommendations.

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LOCATION / VENTILATION

Always operate the welder with the doors closed. Leaving the doors open changes the designed air flow and may cause overheating.

The welder should be located to provide an unrestrict- ed flow of clean, cool air. Also, locate the welder so that engine exhaust fumes are properly vented to an out- side area.

DO NOT MOUNT OVER COMBUSTIBLE SUR-

FACES.

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

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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.

suspended from lift bail.

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

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

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

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

4.Typical conditions of use, i.e., travel speed; rough- ness of surface on which the trailer will be operat- ed; environmental conditions; likely maintenance.

5.Conformance with federal, state, and local laws. (1)

(1)Consult applicable federal, state, and local laws regarding specific requirements for use on pub- lic highways.

VEHICLE MOUNTING

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 compo- nents such as suspension, axles and tires.

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

???Follow vehicle manufacture??s instructions.

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

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

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

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sion may cause overflow.

------------------------------------------------------------------------DIESEL FUEL ONLY

PIPELINER?? 200D PERKINS

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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

PIPELINER?? 200D PERKINS

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

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

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

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

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

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(1) arc volts on a 60% duty cycle. Duty cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period.

(1) The ???Lincoln Plus??? output rating at 60% duty cycle is 200 amperes at 40 Volts.

CONTROL OF WELDING CURRENT

DO NOT TURN THE ???CURRENT RANGE SELEC- TOR??? WHILE WELDING because the current may arc between the contacts and damage the switch.

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

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

PIPELINER?? 200D PERKINS

BB-5OPERATIONBB-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.

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

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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:

??? 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

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

PIPELINER?? 200D PERKINS

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

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

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

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

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

PIPELINER?? 200D PERKINS

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MOVING PARTS can injure.

??? Do not operate with doors open or guards off.

??? Stop engine before servicing.

??? Keep away from moving parts.

See----------additional--------------------------------------------------------------warning information at front of this operator??s manual.

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GENERAL INSTRUCTIONS

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

2.???Current Range Selector??? contacts should not be greased. To keep the contacts clean, rotate the cur- rent control through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before start- ing to weld.

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

PIPELINER?? 200D PERKINS

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AAA-1 TABLE OF CONTENTS - INSTALLATION SECTION AAA-1

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

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

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

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

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

PIPELINER?? 200G

READ the engine operating and maintenance instruc- tions supplied with this machine.

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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 Operator??s Manual. Make sure fuel valve on the sediment bowl is in the open position.

COOLING SYSTEM

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

GASES FROM BATTERY can explode.

??? Keep sparks, flame and cigarettes away.

BATTERY ACID can burn eyes and skin.

??? Wear gloves and eye protection and be careful when boosting, charging or work-

ing near battery.

To prevent EXPLOSION when:

a) Installing a new battery - disconnect the negative cable from the old battery first and connect the negative cable to the new battery last.

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.

??? 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 regulat- ed when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.

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

GROUND.

PIPELINER?? 200G

Return to Master TOC

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

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

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

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

PIPELINER?? 200G

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

ELECTRIC SHOCK can kill.

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

??? Insulate yourself from work and ground

??? Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

??? Do not operate with doors open or guards off.

??? Stop engine before servicing.

??? Keep away from moving parts.

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

See additional warning information at front of this operator??s manual.

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

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

------------------------------------------------------------------------GENERAL DESCRIPTION

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 con- stant voltage output for running the LN-25 wire feeder.

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

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.

Control Panel

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

The control panel also contains a three prong ground- ing type receptacle for auxiliary power.

Welding Generator

The Pipeliner?? 200G uses the old style, round, all cop- per FJW Generator frame which provides the customer with the original ???Classic??? pipe welding arc.

Engine Idler

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

Auxiliary Power

1.75 kw of nominal 120V DC. Output voltage is main- tained within ?? 10% at all loads 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.

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 fur- ther adjustment of the OCV. Total OCV adjustment range is about 10 Volts.

ENGINE OPERATION

STARTING THE GM 3.0L ENGINE

???Turn the Idler control switch to ???HIGH???. (Optional)

???Turn the Ignition switch to ???ON???.

???Press the ???Start??? button.

???If the engine fails to start in 20 seconds, wait 30 sec- onds before repeating the above procedure.

???Allow the engine to run at high idle speed for sever- al minutes to warm up. If idle control switch is left in ???Auto??? position , engine will run at 1600 RPM until engine coolant temperature reaches 130??F.

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?? 200G is 200 amperes at 28(1) arc volts on a 60% duty cycle. Duty cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period.

(1)The Lincoln ???plus output??? rating at 60% duty cycle is 200 amperes at 40 Volts.

PIPELINER?? 200G

DO NOT TURN THE ???CURRENT RANGE SELEC- TOR??? WHILE WELDING because the current may arc between the contacts and damage the switch.

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

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

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

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

TBI DEICING SYSTEM

The welder has been designed to allow continuous year-round operation. Engine coolant is channeled through the TBI housing to prevent the build up of ice on the TBI throat around the throttle plate. the elec- tronic controller is programmed to automatically com- pensate for the build up of ice on the throttle plate. There will be no noticeable change in the operation of the welder should icing develop. On start-up, there is a possibility for the engine to overspeed (to a maximum of 2000 RPM) for up to 10 seconds after throttle body icing conditions have occurred. The electronic gover- nor will correct itself for the new operating conditions and normal operation will resume.

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

PIPELINER?? 200G

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

(K924-4) REMOTE CONTROL

For machines having Code Number 10660:

For ???Stick??? operation which contains switch, remote control rheostat and 100 ft (30.5m) or 25 ft (7.6m) cable. Easy Installation.

(K924-5) REMOTE CONTROL

For machines having Code Number 10913:

For ???Stick??? operation containing remote control rheostat and 100 ft (30.5m) cable. Easy Installation.

REMOTE CONTROL (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.

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

CCC-2

OPTIONAL EQUIPMENT

(K704) Accessory Set

CCC-2

ACCESSORIES

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

PIPELINER?? 200G

Return to Master TOC

DDD-1 TABLE OF CONTENTS - MAINTENANCE SECTION 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

PIPELINER?? 200G

GENERAL INSTRUCTIONS

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

2. ???Current Range Selector??? contacts should not be greased. To keep the contacts clean, rotate the cur- rent control through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before start- ing to weld.

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

MOVING PARTS can injure.

??? Do not operate with doors open or guards off.

??? Stop engine before servicing.

??? Keep away from moving parts.

-------See ---additional--------------------------------------------------------------warning information at front of this operator??s manual.

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

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when neces- sary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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

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

ELECTRIC SHOCK can kill.

??? 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.

DDD-2

SAFETY PRECAUTIONS

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

ENGINE MAINTENANCE

Refer to the Engine??s operation and maintenance man- ual for additional information on the engine.

PIPELINER?? 200G

ENGINE SERVICE

EVERY DAY OR EVERY 8 HOURS

FIRST SERVICE-(50 HOURS)

EVERY 100 HOURS OR 3 MONTHS

EVERY 200 HOURS OR 6 MONTHS

EVERY 600 HOURS OR 12 MONTHS

ENGINE SERVICE (NOTE 2)

ICoolant level

IRadiator for contamination or blockage

IEngine oil level (NOTE 1)

IAlternator / fan belt wear

ILeaks or engine damage

(1)Consult Engine Operators Manual for oil recommendations.

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

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

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

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

These preventive maintenance periods apply to average conditions of operation.S20919-3 If necessary use shorter periods.

PIPELINER?? 200G

Return to Master TOC

E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1

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

PIPELINER?? 200

GLOW PLUGS

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 con- trol and protection modules monitor engine oil pres- sure, coolant temperature and engine RPM. The sys- tem shuts the engine down in the event of a sudden low oil pressure or high coolant temperature. A warn- ing light on the control panel provides fault codes, or on some models the engine fault light will glow.

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

When the welding or auxiliary load is removed a preset time delay of about 15 seconds starts. After approxi- mately 15 seconds of ???no load??? the engine con- trol/protection circuitry returns the engine to low idle RPM.

PIPELINER?? 200

BATTERY

PERKINS DIESEL

ENGINE

ALTERNATORCOUPLED TO

GLOW PLUGS

GENERATOR

12 VOLT

BATTERY

BATTERY, STARTER, ENGINE

ALTERNATOR, OIL, & TEMPERATURE

SWITCH CIRCUITS

PIPELINER?? 200

ENGINE

IGNITION

SWITCH

ENGINE

ALTERNATOR

12 VOLT

BATTERY

BATTERY, STARTER, ENGINE

ALTERNATOR, OIL, & TEMPERATURE

SWITCH CIRCUITS

PIPELINER?? 200

DC GENERATOR MACHINES

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

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

PIPELINER?? 200

F-13TROUBLESHOOTING & REPAIRF-13

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 trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

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

MATERIALS NEEDED

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

PIPELINER?? 200

F-15TROUBLESHOOTING & REPAIRF-15

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, careful- ly check the DC voltage at the brush holders. See Figure F.2. The right side brush holder is positive polarity. Normal DC voltage is 125 - 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.

PIPELINER?? 200

F-16TROUBLESHOOTING & REPAIRF-16

DC EXCITER TEST (continued)

FIGURE F.3 ??? BRUSH HOLDER LEADS

SHUNT COIL AND SERIES COIL

RESISTANCE TESTS

7. Turn the engine OFF.

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

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

Note: Two coils make up a set (L8707), and each coil consists of two coils, wound together. An Exciter Shunt Field Coil and an Exciter Series Coil.

10. The coil leads should be disconnected from the positive and negative brush holder and also the bolted connection within the exciter bracket that connects T12 to the RED lead.

11. Using the Ohmmeter, measure the Exciter Series Coils from the T12 and T2 (heavy stiff magnet wire) and the Exciter Shunt Field Coils from T4 and T14 (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.

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 resis- tances vary significantly, REPLACEMENT MAY

BE NECESSARY.

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

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

PIPELINER?? 200

F-17TROUBLESHOOTING & REPAIRF-17

IDLER SOLENOID TEST

WARNING

TEST DESCRIPTION

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

MATERIALS NEEDED

External 12VDC supply

Wiring Diagram

Volt/ohmmeter (Multimeter)

PIPELINER?? 200

F-19TROUBLESHOOTING & REPAIRF-19

MAIN GENERATOR SHUNT FIELD WINDING TEST

WARNING

TEST DESCRIPTION

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

MATERIALS NEEDED

Volt/ohmmeter (Multimeter)

Wiring Diagram

PIPELINER?? 200

F-21TROUBLESHOOTING & REPAIRF-21

MAIN GENERATOR SHUNT FIELD WINDING TEST (continued)

FIGURE F.6 ??? PLUG P10 PIN ASSIGNMENTS

PIN 3

PIN 5

TAB

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 resis- tance 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 resis- tance 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.

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 specifi- cations, 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.

PIPELINER?? 200

F-23TROUBLESHOOTING & REPAIRF-23

FLASHING THE FIELDS

WARNING

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

PIPELINER?? 200

FLASHING THE FIELDS (continued)

FIGURE F.8 - BRUSH HOLDER/BATTERY JUMPER CONNECTIONS

3.Raise one exciter brush off the armature commuta- tor.

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.

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.

PIPELINER?? 200

F-27TROUBLESHOOTING & REPAIRF-27

ENGINE ALTERNATOR TEST

WARNING

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

PIPELINER?? 200

F-28TROUBLESHOOTING & REPAIRF-28

ENGINE ALTERNATOR TEST (CONTINUED)

FIGURE F.9 - ALTERNATOR LEAD LOCATIONS

BACK OF ALTERNATOR

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 run- ning.

4. Place the idle switch in the ???HIGH IDLE??? posi- tion, start the engine, and allow it to run at high idle speed for about 15 to 30 seconds.

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

6. If the meter reads correctly the engine alterna- tor 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.

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

Alternator

Output

Leads

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 termi- nal. Place the positive meter probe on the bat- tery 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 connec- tions 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.

PIPELINER?? 200

F-29TROUBLESHOOTING & REPAIRF-29

OIL PRESSURE - TEMPERATURE SWITCH TEST

WARNING

TEST DESCRIPTION

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

MATERIALS NEEDED

OhmMeter

PIPELINER?? 200

F-30TROUBLESHOOTING & REPAIRF-30

OIL PRESSURE - TEMPERATURE SWITCH TEST (CONTINUED)

FIGURE F.10 - SWITCH

TEMP SW. / SENDER

S17026-3

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 normal- ly 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 fol- lows.

??? 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.

PIPELINER?? 200

Temperature Switch/Sender Resistance Test. S25162 (Kubota and Perkins Only)

PROCEDURE

1. With the engine not running, and at room temperature, locate the Temperature 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 normal- ly open switch and should read a very high resistance.

4. This switch should close at approximately

230F. This over temperature condition would shut off the engine.

5. Using the ohmmeter check the resistance from terminal G to case ground. At room tempera- ture this resistance should be approximately 520 ohms.

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

??? 140F equals approximately 134 ohms

??? 194F equals approximately 51 ohms

??? 212F equals approximately 39 ohms

7. Replace the two leads previously removed.

PIPELINER?? 200

F-33TROUBLESHOOTING & REPAIRF-33

CURRENT SENSOR PCB TEST

WARNING

TEST DESCRIPTION

This test is used to quickly determine if the current sensor PCB is defective.

MATERIALS NEEDED

Volt/Ohm Meter Electrical Diagrams

Wiring Diagram (Seesection of this manual)

PIPELINER?? 200

F-34TROUBLESHOOTING & REPAIRF-34

CURRENT SENSOR PCB TEST (CONTINUED)

FIGURE F.11 - CASE COVERS

BOLT / NUT (4)

???L???DOOR HOOKS (4)

PROCEDURE

1. Turn the engine off.

2. Remove the four nuts and bolts holding the case top and doors assembly to the welder frame. See Figure F.11.

3. Remove the rubber gasket from the top. Carefully lift up and remove the ???L??? shaped door hooks. Locate the Current Sensing P.C. Board on the inside of the front panel. See Figure

F.12.

4. Turn the engine on and record the voltage between pins 1 and 2 of J1. See Wiring Diagram. This voltage should be approximate- ly 12 VDC (battery voltage).

5. Turn the engine back OFF and locate pins 4 and 2 on J1 of the Current Sensor PCB and place the Volt/Ohm Meter leads into the back of the molex plug.

6.Turn the engine on and record the voltage between pins 4 and 2 on J1. The Idler Switch must be in the ???Auto??? position. This voltage should be approximately 12 VDC (battery volt- age). With the engine running load the 115 VDC auxiliary receptacle or strike an arc using either a load bank or the welding leads. Observe the Volt/Ohm Meter; the 12 VDC should drop to zero. If the 12 VDC drops to zero the current sensor PCB is operating cor- rectly. If the voltage does not drop to zero replace the current sensor PCB.

PIPELINER?? 200

F-37TROUBLESHOOTING & REPAIRF-37

ENGINE THROTTLE ADJUSTMENT TEST

(PERKINS ONLY)

WARNING

TEST DESCRIPTION

If the machine output is low, or high, this test will determine whether the engine is operat- ing at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for adjusting the throttle to the correct RPM are given.

MATERIALS NEEDED

Miscellaneous Hand Tools

Strobe-tach, frequency counter, oscilloscope, white or red marking pencil

PIPELINER?? 200

F-38TROUBLESHOOTING & REPAIRF-38

ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)

(PERKINS ONLY)

FIGURE F.13 - BLOWER PADDLE MARK LOCATION

PROCEDURE

Strobe Tach Method

1. Turn the engine off.

2. Unlatch, lift and secure the right side door. Note: Latches are located at both ends of the

door.

3. Using a white or red marking pencil, place a mark on one of the blower paddles or on the side of the flywheel. See Figure F.13 for loca- tion.

4. Connect the strobe-tach according to the manufacturer??s instructions.

5.Start the engine and direct the strobe-tach light on the blower paddle. Synchronize it to the rotating mark.

With the machine at HIGH IDLE the tach should read between 1540 and 1650 RPM. With the machine at LOW IDLE the tach should read between 1375 and 1425 RPM.

PIPELINER?? 200

F-39TROUBLESHOOTING & REPAIRF-39

ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED)

PROCEDURE

(PERKINS ONLY)

6. If either of the readings is incorrect, adjust the throt- tle as follows:

Adjust HIGH IDLE:

The Engine is Preset at factory. Contact Perkins @ 1-888-737-5364 or www.perkins.com

Adjust LOW IDLE:

First make sure there is no load on the machine. Set the IDLE switch to AUTO and wait for the engine to change to low idle speed.

Use the 7/16??? wrench to loosen the solenoid idle rod locking nut. See Figures F.13 & F.14 Turn the rod to change the amount of throw in the lever arm, until the tach reads between 1375 and 1425 RPM. Retighten the locking nut. Make sure the lever arm does not contact low speed adjustment stop. Back stop out if necessary.

PIPELINER?? 200

F-45TROUBLESHOOTING & REPAIRF-45

DC EXCITER ARMATURE & FIELD COILS

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the exciter armature and field coils.

MATERIALS NEEDED

3/8??? Wrench

1/2??? Wrench

1-5/8??? Socket wrench Wiring Diagram

PIPELINER?? 200

F-46TROUBLESHOOTING & REPAIRF-46

DC EXCITER ARMATURE & FIELD COILS

REMOVAL AND REPLACEMENT PROCEDURE

FIGURE F.15 ??? EXCITER COVER REMOVAL

FLAT WASHER

ARMATURE LOCKING NUT

EXITER COVER

PROCEDURE

DC Exciter Armature Removal Procedure

1. Turn the engine OFF.

2. Using the 3/8??? nut driver, remove the exciter cover. See Figure F.15.

3. Using the 3/8??? wrench, remove the two brush holder assemblies. Note insulator placement for reassembly.

4. Bend the flat washer away from the armature locking nut.

5. Using the 1-5/8??? socket wrench, remove the armature locking nut, washer, and sleeve col- lar.

6. Carefully remove the armature by sliding it from the shaft.

NOTE: The sleeve collar may have to be removed with a gear puller. Be careful not to damage the armature commutator.

Reassembly:

7. Upon reassembly, the armature locking nut should be torqued to 170 ft.-lbs. Install a new sleeve collar if necessary (Part number T5345). Bend the flat washer against the locking nut.

8. Install the brush holder assemblies. Note insulator placement.

9. Check the armature air gap. Minimum gap should be .025???.

10. Install the exciter cover.

PIPELINER?? 200

F-49TROUBLESHOOTING & REPAIRF-49

MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE

WARNING

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the main DC generator frame.

MATERIALS NEEDED

Rope sling

Wood or steel blocks

Pry bars

9/16??? Wrench

1/2??? Wrench

7/16??? Wrench

3/4??? Wrench

Slot head screw driver

Wiring Diagram

PIPELINER?? 200

F-52TROUBLESHOOTING & REPAIRF-52

MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

FIGURE F.18 ??? FUEL TANK MOUNTING DETAILS

FUEL TANK

BOLTS / NUTS / WASHERS (4)

FUEL LINE

FUEL BOWL

RAILS

5.Perform the DC Exciter Armature Removal

Procedure.

6.Turn off the fuel supply at the fuel bowl and remove the fuel line. Plug the line to avoid spillage.

7.Using the 9/16??? wrench, remove the four nuts, bolts, and washers holding the fuel tank assembly to the rails. See Figure F.18.

8.Carefully remove the fuel tank and set it aside in a safe area.

PIPELINER?? 200

F-55TROUBLESHOOTING & REPAIRF-55

MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

FIGURE F.22 ??? FRONT PANEL WIRING CONNECTIONS

13.Using the slot head screw driver, remove the red lead connecting the 115VDC receptacle to the DC exciter. See Figure F.22 and the Wiring Diagram. Cut any necessary cable ties.

14.Remove the leads connecting the idler PC board to the DC exciter. See Figure F.22 and the Wiring Diagram. Cut any necessary cable ties.

15.Disconnect the blue and brown main shunt leads from their quick disconnect splices. See the Wiring Diagram.

16.Disconnect the leads from the START button switch. See Figure F.22 and the Wiring Diagram.

17.Remove the leads from the ignition switch. Label for reassembly. See Figure F.22 and the Wiring Diagram.

18.Using the 3/8??? nut driver, remove the leads from the ammeter. Label for reassembly. See Figure F.22 and the Wiring Diagram.

19.Label and remove the leads from the idler switch. See Figure F.22 and the Wiring Diagram.

20.Remove leads from the Idler Solenoid. See Wiring Diagram.

PIPELINER?? 200

F-56TROUBLESHOOTING & REPAIRF-56

MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

FIGURE F.23 ??? FRONT PANEL FASTENER REMOVAL

BOLTS / NUTS / WASHERS (2)

MIDDLE SCREW (1)

BASE MOUNTING BOLTS (4)

23.Using the 1/2??? wrench, remove the two bolts, nuts, and washers that hold the front panel assembly to the horizontal rails. (There is one on each side.) See Figure F.23.

24.Using the 9/16??? wrench, remove the four bolts, nuts, and washers from the bottom of the front panel assembly. These four bolts mount the front to the base. (There are two on each side.) See Figure F.23.

25.Using the 3/8??? nut driver, remove the screw from the lower middle of the front panel. See Figure F.23.

26.Carefully remove the front panel assembly.

PIPELINER?? 200

F-58TROUBLESHOOTING & REPAIRF-58

MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

FIGURE F.26 ??? MAIN GENERATOR FEET MOUNTING

MAIN GENERATOR

FEET (2)

REMOVE MOUNTING

NUTS, WASHERS,

AND BOLTS

30.Using the 3/4??? wrench, remove the frame mounting bolts, nuts, and washers from the feet of the main generator. See Figure F.26.

FIGURE F.27 ??? MAIN GENERATOR ENGINE MOUNTING

SLING

ENGINE / GENERATOR

MOUNTING HOLES

PIPELINER?? 200

F-61TROUBLESHOOTING & REPAIRF-61

MAIN GENERATOR ARMATURE

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the main arma- ture.

MATERIALS NEEDED

Rope sling 5/8??? Wrench

Wood or steel blocks

PIPELINER?? 200

F-62TROUBLESHOOTING & REPAIRF-62

MAIN GENERATOR ARMATURE

REMOVAL AND REPLACEMENT PROCEDURE

FIGURE F.28 ??? MAIN GENERATOR ARMATURE MOUNTING

PROCEDURE

1. Turn the engine OFF.

2. Perform the DC Exciter Armature Removal

procedure.

3. Perform the Main Generator Frame

Removal procedure.

4. Using the rope sling, support the armature.

5. Make sure the engine supported with the wood or steel blocks.

6. Using the 5/8??? wrench, remove the eight bolts and lock washers holding the blower paddles and the armature to the engine flywheel. See Figure F.28.

7. With the armature supported and ???balanced??? in the rope sling, carefully rotate the armature 1/8 turn in either direction to release it.

CAUTION

The armature is now free to be removed from the engine.

SLING

BLOWER PADDLE

MOUNTING BOLTS /

LOCK WASHERS (8)

Replacement: Refer to Figure F.28

1. Support the armature with the rope sling. Mount the armature to the engine, rotating it 1/8 turn in either direction to achieve attach- ment. Before removing the rope sling, be careful to support the armature with the wood or steel blocks under the engine. With the 5/8??? wrench, install the eight bolts and lock washers that attach the blower paddles and the armature to the engine flywheel.

2. Perform other replacement procedures according to each of the following:

Generator Frame Removal and

Replacement

DC Exciter Armature Removal and

Replacement

PIPELINER?? 200

Return to Master TOC

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram - Code 10660 - (L11402) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2 Wiring Diagram - Code 10913, 11136 - (L11864) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3 Wiring Diagram - Code 10929 - (M20056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4 Wiring Diagram - Code 11114, 11316 - (M20464) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5 Wiring Diagram - Code 11471 - (M21564) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 Schematic ??? Complete Machine - Code 10929 - (L12020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7 Schematic ??? Complete Machine - Code 11114. 11316 - (L12362) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8 Schematic ??? Complete Machine - Code 11471 - (L13350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9 Schematic ??? Current Sense PC Board - Code 10929, 11114, 11316, 11471 - (S25973) . . . . . . . . . . . . .G-10 Schematic ??? Idler / Engine Shutdown - Code 10929 - (L10826) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11

* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay- ered and are therefore considered to be unserviceable. Assembly drawings of these boards are no longer provided.

PIPELINER 200

Return to Section TOC Return to Master TOC

Section TOC Master TOC

K924-5 REMOTE CONTROL (OPTIONAL)

RESISTORS

REMOTE CONTROL

POTENTIOMETER BOX

WIRE FEED MODULE (OPTIONAL)

ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".

CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

Return to Return to

L11864

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

PIPELINER?? 200