Lincoln Electric PIPELINER 200D KUBOTA, Operator'S Manual

Page 1: ...NT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful PIPELINER 200D For use with machines having Code Numbers 10929 IM769 October 2004 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in...

Page 2: ...S SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from...

Page 3: ...rth 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...

Page 4: ...e 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 Cu...

Page 5: ...rans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le la...

Page 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Page 7: ..._____________________________________ Accessories Section C Optional Equipment Field Installed C 1 ________________________________________________________________________ Maintenance Section D Safety Precautions D 1 General Instructions D 1 Cooling System D 1 Engine Maintenance D 1 Bearings D 2 Commutator and Brushes D 2 Idler Maintenance D 2 Nameplates D 2 Purging Air from Fuel System D 2 D 3 En...

Page 8: ...N 200 Amp DC Welder All Copper Windings Pure DC Power Generator Make Model Description Horsepower Operating Displacement cu in ltrs Starting Capacities SPEED System INPUT DIESEL ENGINE Perkins 104 22 4 Cylinder 4 Stroke Naturally Aspirated Water Cooled Engine 28 2 HP 1600RPM High 1600RPM Full Load 1550RPM Low Idle 1400RPM 135 6 2 2 12VDC Battery and starter Push Button Starter 650 Cold crank amps ...

Page 9: ... are properly vented to an outside area 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 ...

Page 10: ...ment 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 r...

Page 11: ...r 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 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 ...

Page 12: ... CYCLE 200A 28V 60 200A 40V 60 The unit is also capable of providing 1 80 kw of 120V DC auxiliary power at 35 duty cycle maximum This unit uses the PERKINS 104 22 Industrial water cooled diesel engine DESIGN SUMMARY Control Panel Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine The welder controls consist of a five step Current Range Selec...

Page 13: ...ain The engine controls were prop erly set at the factory and should require no adjust ing when received COLD WEATHER STARTING With a fully charged battery and a proper weight oil the engine should start satisfactorily even down to about 15 F 26 C If the engine must be frequently started at or below 15 F 26 C it may be desirable to install cold starting aides Note Extreme cold weather starting may...

Page 14: ... 3 Periodically shut off the engine and check the crankcase oil level B 3 OPERATION B 3 PIPELINER 200D WELDER OPERATION 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 ...

Page 15: ...ifications for operating speeds The idler is controlled by the Idler toggle switch on the welder control panel The switch has two posi tions as follows 1 In the High position the idler solenoid acti vates and the engine goes to high idle speed The speed is controlled by the governor 2 In the Auto position the idler oper ates as follows When welding or drawing power for lights or tools approximatel...

Page 16: ...use consult applicable federal state and local laws regarding possible additional requirements Choice of 2 hitches and add on fender light package Order K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender Light Kit 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 ...

Page 17: ... cooling system periodi cally to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type ENGINE MAINTENANCE Refer to the Engine s operation and mainte nance manual for additional information on the engine Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be neces sary t...

Page 18: ...d be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experienced mainte nance 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 ...

Page 19: ...lter canister I Drain water separator fuel strainer Engine oil NOTE 1 3 R Engine oil level NOTE 1 Coolant NOTE 3 MAINTENANCE ITEM Concentration of antifreeze C I R Coolant level R C R R I R I EVERY 600 HOURS OR 18 MONTHS S25557 Contact Perkins Intake 008 exhaust 008 Donaldson P181050 Nelson 70206N R Replace C Clean Battery Leaks or engine damage I Injector performance All nuts and bolts for tightn...

Page 20: ...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 ac...

Page 21: ...commutator 2 Brushes may be worn down to limit 3 Field circuit may have variable resistance connection or intermit tent open circuit due to loose or broken wire 4 Electrode lead or work lead con nection may be poor 5 Wrong grade of brushes may have been installed on generator 6 Field rheostat may be making poor contact and overheating 1 Generator or exciter brushes may be loose or missing 2 Excite...

Page 22: ...utator start the welder and the generator voltage should build up E 3 TROUBLESHOOTING E 3 PIPELINER 200D Observe all Safety Guidelines detailed throug out this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CA...

Page 23: ...the fuel system 5 Clogged fuel filter 6 Irregular and faulty fuel supply Injector pump trouble 7 Glow plug not heated 8 Improper viscosity of the lubricat ing oil 9 Clogged air cleaner 10 No compression 11 Engine protection light is on 12 Defective governor 13 Engine defective 1 Lack of fuel 2 Clogged fuel filter 3 Air mixed in the fuel system 4 Faulty function of the engine 1 Overheating of the e...

Page 24: ...n after the ignition switch has been in the on position for more than 60 seconds with the engine not started 1 Excess engine oil 2 Too low viscosity of the engine oil 3 Faulty injection timing 1 Unsuitable fuel 2 Excess injection 3 Faulty function of the engine 4 Overloading 5 Clogged air cleaner 1 Loose fan belt 2 Faulty wiring 3 Faulty battery 4 Worn out alternator brush 1 Loose or damaged wirin...

Page 25: ...n Replace Idler Idler Solenoid Coil Control Switch 12 VDC 0 VDC Check Continuity of Check for Jamming Current sensor from Idler of the Idler Solenoid PC Board Terminal Mechanism or a broken to Ground Terminal Return Spring Open Closed 1 Check Wiring in Replace Current Idler Solenoid Sensor Circuit 2 Replace Idler P C Board If for any reason you do not understand the test procedures or are unable t...

Page 26: ...2 Check for Jamming of the Idler Solenoid Mechanism 3 Check Idler Circuit Wiring and Repair as Required 4 Replace Idler P C Board Current sensor may be defective and not closed To Check Short the Lead from current sensor to P C Board to the Welder Frame If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorize...

Page 27: ...E GAUGE ALTERNATOR OIL PRESSURE GAUGE GROUND TO BASE GROUND TO ENGINE TEMPERATURE SWITCH SENDER OIL PRESSURE SWITCH SENDER PLUG FOR REMOTE CONTROL POTENTIOMETER REMOTE CONTROL POTENTIOMETER BOX SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION PLUG P5 ELECTRICAL SYMBOLS PER E1537 WIRE FEED MODULE MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS ON MACHINE REMOVE PLUG P10 FROM CON...

Page 28: ...rld s orld s Le Leader in W er in Welding an and Cu Cutting Prod Products S26097 A A 01 RESISTORS Y X B G W F G ORANGE WHITE JUM E JUMPER WHITE JUM E JUMPER PIN CABLE CONNEC BLE CONNEC TION ION TABLE BLE C D E LEAD C COLOR RED BLUE CV WIRE CONT CONTROL P POT CCW BLUE RED ORANGE REMOTE C CONTROL B ROL BOX CONNECT T TO CA CASE K2 K2464 1 REMOT REMOTE CONT CONTROL W WIRING NG CONNECT CONNECTION DI N ...

Page 29: ...24 00 37 12 66 50 27 50 12 25 4 00 4 00 23 00 8 25 41 66 3 25 57 70 O 56 SKID MOUNTING HOLE O 56 SKID MOUNTING HOLE N B N B N A NOTES N A CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE BUT NO FUEL N B Ø 56 TRAILER MOUNTING HOLES 20 62 18 50 40 94 45 50 ...

Page 30: ...NOTES PIPELINER 200D ...

Page 31: ...NOTES PIPELINER 200D ...

Page 32: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 33: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 34: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...