i

SAFETY

i

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

The Above For Diesel Engines

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.

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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 vaporiz- ing 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.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.

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.

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.

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 circum- stances, 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 spe- cific 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 vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating prod- ucts.

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

5.f. Also see item 1.b.

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SAFETY

iii

WELDING and CUTTING

SPARKS can

cause fire or explosion.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent 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 adjacent 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 though they have been ???cleaned???. For information, purchase ???Recommended

Safe Practices for the Preparation for Welding and Cutting of 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.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil 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 cir- cuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

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.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders

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

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.

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 manufacturer???s recommendations.

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

iv

SAFETY

iv

PR??CAUTIONS DE S??RET??

Pour votre propre protection lire et observer toutes les instructions et les pr??cautions de s??ret?? specifiques qui parraissent dans ce manuel aussi bien que les pr??cautions de s??ret?? g??n??rales suiv- antes:

S??ret?? Pour Soudage A L???Arc

1.Protegez-vous contre la secousse ??lectrique:

a.Les circuits ?? l?????lectrode et ?? la pi??ce sont sous tension quand la machine ?? souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v??tements mouill??s. Porter des gants secs et sans trous pour isoler les mains.

b.Faire tr??s attention de bien s???isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couch?? pour lesquelles une grande partie du corps peut ??tre en contact avec la masse.

c.Maintenir le porte-??lectrode, la pince de masse, le c??ble de soudage et la machine ?? souder en bon et s??r ??tat defonctionnement.

d.Ne jamais plonger le porte-??lectrode dans l???eau pour le refroidir.

e.Ne jamais toucher simultan??ment les parties sous tension des porte-??lectrodes connect??s ?? deux machines ?? souder parce que la tension entre les deux pinces peut ??tre le total de la tension ?? vide des deux machines.

f.Si on utilise la machine ?? souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-??lectrode s???applicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se prot??ger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le c??ble-??lectrode autour de n???importe quelle partie du corps.

3.Un coup d???arc peut ??tre plus s??v??re qu???un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant appropri?? ainsi qu???un verre blanc afin de se prot??ger les yeux du ray- onnement de l???arc et des projections quand on soude ou quand on regarde l???arc.

b.Porter des v??tements convenables afin de prot??ger la peau de soudeur et des aides contre le rayonnement de l???arc.

c.Prot??ger l???autre personnel travaillant ?? proximit?? au soudage ?? l???aide d?????crans appropri??s et non-inflammables.

4.Des gouttes de laitier en fusion sont ??mises de l???arc de soudage. Se prot??ger avec des v??tements de protection libres de l???huile, tels que les gants en cuir, chemise ??paisse, pan- talons sans revers, et chaussures montantes.

5.Toujours porter des lunettes de s??curit?? dans la zone de soudage. Utiliser des lunettes avec ??crans lateraux dans les zones o?? l???on pique le laitier.

6.Eloigner les mat??riaux inflammables ou les recouvrir afin de pr??venir tout risque d???incendie d?? aux ??tincelles.

7.Quand on ne soude pas, poser la pince ?? une endroit isol?? de la masse. Un court-circuit accidental peut provoquer un ??chauffement et un risque d???incendie.

8.S???assurer que la masse est connect??e le plus pr??s possible de la zone de travail qu???il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d???autres endroits ??loign??s de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev- age, c??bles de grue, ou autres circuits. Cela peut provoquer des risques d???incendie ou d???echauffement des chaines et des c??bles jusqu????? ce qu???ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuli??rement important pour le soudage de t??les galvanis??es plomb??es, ou cadmi??es ou tout autre m??tal qui produit des fume??s toxiques.

10.Ne pas souder en pr??sence de vapeurs de chlore provenant d???op??rations de d??graissage, nettoyage ou pistolage. La chaleur ou les rayons de l???arc peuvent r??agir avec les vapeurs du solvant pour produire du phosg??ne (gas fortement toxique) ou autres produits irritants.

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

PR??CAUTIONS DE S??RET?? POUR

LES MACHINES ?? SOUDER ??

TRANSFORMATEUR ET ??

REDRESSEUR

1.Relier ?? la terre le chassis du poste conformement au code de l?????lectricit?? et aux recommendations du fabricant. Le dispositif de montage ou la piece ?? souder doit ??tre branch?? ?? une bonne mise ?? la terre.

2.Autant que possible, I???installation et l???entretien du poste seront effectu??s par un ??lectricien qualifi??.

3.Avant de faires des travaux ?? l???interieur de poste, la debranch- er ?? l???interrupteur ?? la boite de fusibles.

4.Garder tous les couvercles et dispositifs de s??ret?? ?? leur place.

v

Thank You

v

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

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

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 volt- age output for running the LN-25 wire feeder.

The optional Remote Control Kit provides a remote control rheostat for remote fine current and open cir- cuit 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 V2403M 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 ground- ing type receptacle for auxiliary power, an engine tem- perature gauge, a battery charging ammeter an oil pressure gauge and a high idle RPM adjustment knob.

WELDING GENERATOR

The Pipeliner?? 200D KUBOTA uses the old style, round, all copper FJW Generator frame which pro- vides the customer with the original ???Classic??? pipe welding arc.

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 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.

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.

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 RPM???S. This is to allow further adjustment of the OCV. Total OCV adjustment range is about 15 volts.

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

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

PRE-OPERATION INSTALLATION

WARNING

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

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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 the 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 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 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

outside area.

CAUTION

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 gen- eral, 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 insulat- ed 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

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TRAILER (See Optional Features)

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

With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail. (See size recommendations below.) For positive polarity, connect the electrode cable to the terminal marked ???+???. For Negative polarity, con- nect the electrode cable to the ???-??? stud. These con- nections 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.

RECOMMENDED COPPER CABLE SIZES

PRE-OPERATION SERVICE

CAUTION

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

WARNING

???Stop engine while fueling.

???Do not smoke when fueling.

??? Keep sparks and flame away from tank.

???Do not leave unattended while fueling.

???Wipe up spilled fuel and allow

fumes to clear before starting engine.

??? Do not overfill tank, fuel expan- sion may cause overflow.

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

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OIL

This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the engine operation manual for specific engine manufacturer???s recommendations. Upon receipt of the welder, check the engine dipstick to be sure the oil is at the ???full??? mark. DO NOT overfill.

FUEL

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

COOLING SYSTEM

The radiator has been filled at the factory with a 50-50 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).

ENGINE OPERATION

WARNING

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

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

ELECTRIC SHOCK can kill.

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

???Insulate yourself from work and ground

???Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

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

??? Stop engine before servicing.

??? Keep away from moving parts.

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

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

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 V2403M

DIESEL ENGINE

1.Turn the ???IDLER??? switch to ???HIGH???.

2.Turn the ???IGNITION??? switch to ???ON???.

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

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

5.Observe the oil pressure. If no pressure shows within 30 seconds, stop the engine and consult the engine operating manual. To stop the engine, turn the ???IGNI- TION??? 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.

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 cold- starting aides.

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

WARNING

Under NO conditions should ether or other starting fluids be used!

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HIGH ALTITUDE OPERATION:

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

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

STOPPING THE ENGINE

1.Turn the ???IGNITION??? switch to ???OFF???

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

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 person- nel to do this per the instructions in the MAINTE-

NANCE section of this manual.

ENGINE BREAK-IN

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 sub- stance 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 condi- tions for extended periods of time are especially sus- ceptible to the conditions described above. To accomplish successful engine break-in, most diesel- powered equipment needs only to be run at a reason- ably heavy load within the rating of the welder for some period of time during the engine???s early life. However, if the welder is subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be necessary. Caution must be observed in correctly loading a diesel/generator unit.

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

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

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

WELDER OPERATION

WARNING

ELECTRIC SHOCK can kill.

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

???Insulate yourself from work and ground.

FUMES & GASES can be dangerous.

??? Keep your head out of the fumes.

???Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or

explosion.

??? Keep flammable material away.

ARC RAYS can burn.

??? Wear eye, ear, and body protection.

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DUTY CYCLE

The NEMA output rating of the PIPELINER?? 200D KUBOTA is 200 amperes at 28 arc volts on a 60% duty cycle (consult Specifications in this manual for alternate ratings). Duty cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period.

CONTROL OF WELDING CURRENT

CAUTION

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 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.

When a forceful ???digging??? arc is required, usually for vertical and overhead welding, use a higher ???Current Range Selector??? setting and lower open circuit volt- age. 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 tech- niques at settings at the lower end of the open circuit voltage range.

CAUTION

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

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

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.

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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.

WIRE FEED OPTIONS

Wire Feed Module (K623-1) - Provides constant voltage (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25. (Factory installed on the K1643-6).

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

LN-23P Wire Feeder (K316L-1)-Portable CV unit for Innershield pipe welding. Control cable operates con- tactor 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 LN- 23P to any Lincoln power source. Makes 14 pin con- nection 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.

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.

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 neces- sary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is com- plete. Always use the greatest care when work- ing 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.

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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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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.

4.When necessary, remove the sediment bowl, if so equipped, from beneath the fuel tank and clean out any accumulated dirt and water.

5.Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in the engine manufacturer???s manual.

COOLING SYSTEM

The PIPELINER?? 200D KUBOTA is equipped with a pressure radiator. Keep the radiator cap tight to pre- vent loss of coolant. Clean and flush the cooling sys- tem 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 con- stantly or in excessively dirty locations, it may be nec- essary 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. Over- greasing 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 rotat- ing armature when stoning the commutator.

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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.

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 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 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 bat- tery.

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When installing a new battery or using a jumper bat- tery 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 con- nection.

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

2.If desired, the welder can be used without automat- ic idling by setting the ???Idler??? switch to the ???High??? position.

NAMEPLATES

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

PURGING AIR FROM FUEL SYSTEM (KUBOTA V2403M ENGINE)

WARNING

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

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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

FIGURE D.1

2.Turn the engine by pressing the start button until the engine runs smoothly (this should take approxi- mately 10 seconds).

3.Fully close the air bleeding valve by turning it clockwise.

Contact your Kubota Engine repair facility if problems persist.

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

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled ???PROBLEM (SYMP- TOMS)???. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

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

Step 3. RECOMMENDED COURSE OF ACTION

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

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

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

Contact your local Lincoln Authorized Field Service Facility.

Check for loose or disconnected wire running between weld selector switch and output stud.

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

2.Check Idler circuit wiring. Possible Problems are wires from Current Sensing Board reversed at idler switch or wires connected incorrectly at Current Sensor

Molex plug.

1.Load too small. Try load above 100 Watts.

KUBOTA 200D PIPELINER??

NOTES:

N,A. CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT ON FUEL. N.B. ?? 56/14.2 TRAILER MOUNTING HOLES.

45.50

37.12 1155.7

942.85

O. 56 SKID

MONTING HOLE

40.94

1039.88

A.01

S10766-13

5-F

PRINT DIMENSION

5-F