RETURN TO MAIN MENU
IM965-B
®
March, 2010
PIPELINER 200D KUBOTA
For Machines with Code Number 11498, 11591, 11644
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation ... and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
P
I
P
E
L
I
N
E
R
2
0
0
D
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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
Download from Www.Somanuals.com. All Manuals Search And Download.
ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
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.
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.
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.
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.
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.
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.
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
iii
iii
SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
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.
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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.
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.
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
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.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Download from Www.Somanuals.com. All Manuals Search And Download.
v
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!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
Download from Www.Somanuals.com. All Manuals Search And Download.
vi
TABLE OF CONTENTS
vi
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
General Description...............................................................................................A-2
Design Features ....................................................................................................A-2
Pre-Operation Installation......................................................................................A-3
Safety Precautions..........................................................................................A-3
Exhaust Spark Arrester...................................................................................A-3
Location/Ventilation.........................................................................................A-3
Machine Grounding.........................................................................................A-3
Lift Bail ............................................................................................................A-3
Trailers ............................................................................................................A-4
Polarity Control and Cable Sizes ....................................................................A-4
Pre-Operation Service ...........................................................................................A-4
Oil....................................................................................................................A-4
Fuel .................................................................................................................A-4
Cooling System...............................................................................................A-4
Battery Charging .............................................................................................A-5
________________________________________________________________________
Operation .........................................................................................................Section B
Engine Operation...................................................................................................B-1
Starting The Kubota V2403M Engine, Cold Weather Starting .......................B-1
High Altitude Operation...................................................................................B-1
Stopping the engine ........................................................................................B-1
Break-In...........................................................................................................B-1
Welder Operation...................................................................................................B-2
Duty Cycle.......................................................................................................B-2
Control of Welding Current..............................................................................B-2
Idler Operation ................................................................................................B-3
Auxiliary Power ...............................................................................................B-3
Fuel Consumption Data ..................................................................................B-3
________________________________________________________________________
Accessories.....................................................................................................Section C
Optional Features (Field Installed) ........................................................................C-1
Wire Feed Options.................................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Instructions..............................................................................................D-1
Cooling System.....................................................................................................D-1
Bearings................................................................................................................D-1
Commutator and Brushes .....................................................................................D-1
Idler Maintenance..................................................................................................D-2
Nameplates...........................................................................................................D-2
Purging Air from Fuel System................................................................................D-2
Engine Service Chart ............................................................................................D-3
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Welder Troubleshooting ........................................................................................E-2
Engine Troubleshooting Guide ................................................................E-3,E-4,E-5
Electronic Idler Troubleshooting Guide...........................................................E-6,E-7
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagram...................................................................................F-1,F-2,F-3,F-4
Dimension Print......................................................................................................F-5
________________________________________________________________________
Parts List.....................................................................................................P-504 Series
Download from Www.Somanuals.com. All Manuals Search And Download.
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - PIPELINER® 200D KUBOTA
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
4 Cylinder
4 Cycle
Naturally Aspirated
Water-Cooled
Diesel Engine
148.53 cu. in
(2.43 ltrs)
12VDC battery
Fuel: 15 gal.
57 L
(Group 45, 650
cold crank amps)
1.4 KW Starter
40 A. Alternator
w/ built in reg.
Kubota
V2403M
High Idle 1600
Low Idle 1400
Bore x Stroke
Oil: 10.04 Qts.
9.5 L
Coolant 9.5 Qts
Tier 4 interim
Compliant
Cast Iron Cylinder, Full Load 1600
Block/Crankcase
3.43” x 4.03”
.
27.8HP @1600 RPM
9.0 L
RATED OUTPUT @ 104°F(40°C) - WELDER
DESCRIPTION
RATED DC OUTPUT
Duty
DC CURRENT RANGE
VOLTS @ RATED AMPS
CYCLE
Fine Adjustments in each Range
200 Amp DC Welder
All Copper Windings
LINCOLN PLUS RATING 40V @ 200A
NEMA RATING 28V @ 200A
60%
40-300 Amps
Pure DC Power Generator
98V DC Max. OCV @ 1600RPM
RATED OUTPUT @ 104°F(40°C) - GENERATOR
Auxiliary Power (1)
1.75 kW 15 Amps @ 120V DC @ 35% Duty Cycle
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
(2)
45.50 in.
24.00 in.
(610 mm)
68.00 in.
(1727 mm)
1302 lbs.
(592 kg)
(1156 mm)
(1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within 10% at all loads up to rated capacity.
When welding, available auxiliary power will be reduced.
(2) Height is to the top of exhuast elbow. Case height is 40.9 in.(1039mm).
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
A-2
A-2
INSTALLATION
ENGINE IDLER
GENERAL DESCRIPTION
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.
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.
AUXILIARY POWER
1.75 kw of nominal 120V DC. Output voltage is main-
tained within 10% at all loads up to rated capacity.
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.
WELDER ENCLOSURE
The complete welder is rubber mounted on a rugged
steel “C” channel base.
The Pipeliner® 200D KUBOTA has a current range of
40-300 DC amps with output ratings as follows:
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 (-).
RATED OUTPUT
DUTY CYCLE
200A @ 28V
200A @ 40V
60%
60%
CRANKING SYSTEM
A 12V electric starter is standard.
AIR CLEANER
Heavy duty two-stage dry type
The unit is also capable of providing 1.75 kw of 120V
DC auxiliary power.
MUFFLER
A muffler and stainless steel exhaust outlet pipe are
standard.
This unit uses the Kubota V2403M Industrial water
cooled diesel engine.
ENGINE HOUR METER
A meter to record the hours of operation.
DESIGN FEATURES
CONTROL PANEL
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.
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.
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.
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.
OIL DRAIN VALVE- A ball valve, hose and clamp are
standard.
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.
REMOTE CONTROL- The Remote/Local switch and
Receptacle are standard.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
A-3
A-3
INSTALLATION
PRE-OPERATION INSTALLATION
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
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.
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.
------------------------------------------------------------------------
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
MACHINE GROUNDING
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
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.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
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
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
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.
------------------------------------------------------------------------
See additional warning information at the
front of this operator’s manual.
------------------------------------------------------------------------
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not
qualify as a spark arrester. When required by local
regulations, a suitable spark arrester must be installed
and properly maintained.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
WARNING
• Lift only with equipment of
adequate lifting capacity.
CAUTION
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
Use of an incorrect arrester may lead to engine dam-
age or performance loss. Contact the engine manu-
facturer for specific recommendations.
------------------------------------------------------------------------
LOCATION/VENTILATION
FALLING
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bale.
------------------------------------------------------------------------
• Do not lift machine if lift bale is
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
A-4
A-4
INSTALLATION
TRAILER (See Optional Features)
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
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:
Amps
Duty Cycle
Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
200
60%
1
1/0
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.
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.
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.
(1)
5. Conformance with federal, state and local laws.
(1)
Consult your federal, state and local laws regarding specific
requirements for use on public highways.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
VEHICLE MOUNTING
DIESEL FUEL
can
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
cause fire
DIESEL FUEL ONLY-Low sulphur fuel or ultra low
sulphur fuel in U.S.A. and Canada.
------------------------------------------------------------------------
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
OIL
• 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.
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.
• Follow vehicle manufacture’s instructions.
------------------------------------------------------------------------
FUEL
POLARITY CONTROL AND CABLE SIZES
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.
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.) COOLING SYSTEM
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.
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).
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
A-5
A-5
INSTALLATION
Battery Charging
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and
be careful when boosting, charging
or working near battery.
To prevent EXPLOSION when:
a) Installing a new battery - disconnect the nega-
tive cable from the old battery first and con-
nect the negative cable to the new battery last
b) Connecting a battery charger - remove the bat-
tery from the welder by disconnecting the neg-
ative cable first, then the positive cable and
battery clamp. When reinstalling, connect the
negative cable last.
c) Using a booster - connect the positive lead to
the battery first, then connect the negative
lead to the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:
a) Installing a new battery.
b) Using a booster.
Use correct polarity - Negative Ground.
• To prevent BATTERY DISCHARGE, if you have
an ignition switch, turn it off when engine is not
running.
• To prevent BATTERY BUCKLING, tighten nuts
on battery clamp until snug.
------------------------------------------------------------------------
The PIPELINER® 200D KUBOTA is equipped with a
wet charged battery. The charging current is automat-
ically regulated when the battery is low (after starting
the engine) to a trickle current when the battery is fully
charged.
When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
B-1
B-1
OPERATION
COLD WEATHER STARTING:
ENGINE OPERATION
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.
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.
Note: Extreme cold weather staring may require
longer glow plug operation.
-------------------------------------------------------
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.
WARNING
Under NO conditions should ether or other
starting fluids be used!
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION:
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder 4% for every
300 meters (984 ft.) above 1500 meters (4920 ft.).
--------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
Contact a Kubota Service Representative for any
engine adjustments that may be required.
STOPPING THE ENGINE
1. Turn the “IGNITION” switch to “OFF”
------------------------------------------------------------------------
See additional warning information at the
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.
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
When hauling the welder between job sites, close the
valve on the water separator.
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).
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.
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.
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
B-2
B-2
OPERATION
DUTY CYCLE
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.
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.
------------------------------------------------------------------------
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.
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
3. Periodically shut off the engine and check the
crankcase oil level.
WELDER OPERATION
WARNING
Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.
ELECTRIC SHOCK can kill.
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.
• 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.
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.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
CAUTION
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
------------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear, and body protection.
------------------------------------------------------------------------
These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
B-3
B-3
OPERATION
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 posi-
tions as follows:
1. In the “High”
position, the engine control unit
increases the engine to high idle speed.
2. In the “Auto”
/
position, the idler oper-
ates as follows:
a. When welding or drawing power for lights or tools
(approximately 100 watts minimum) from the 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.
Always replace blown fuse with type rated for DC volt-
age (i.e. Cooper Bussmann Inc. Model LP-CC-15 or
Littlefuse Model CCMR-15.
PIPELINER® 200D WITH KUBOTA V2403M DIESEL ENGINE
TYPICAL FUEL CONSUMPTION DATA
Low idle (1400 RPM )
No Load
.39 gal/hr (1.46 ltrs/hr )
.53 gal/hr (2.00 ltrs/hr )
.90 gal/hr (3.42 ltrs/hr )
.54 gal/hr (2.04 ltrs/hr)
High idle ( 1600 Rpm )
No load
200 Amps @ 28 Volts
Auxiliary Power
1,750 Watts
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
C-1
C-1
ACCESSORIES
WIRE FEED OPTIONS
OPTIONAL FEATURES (Field Installed)
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).
GENERAL OPTIONS
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc
welder for pipe thawing is not approved by the
CSA, nor is it recommended or supported by
Lincoln Electric.
------------------------------------------------------------------------
Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.
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.
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.
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.
K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack
LN-25 Wire Feeder (K449)-Portable CC/CV unit for
flux-cored and MIG welding. Includes Gas Solenoid &
Internal Contactor. Requires Wire Feed Module.
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 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.
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.)
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.
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.
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
4. When necessary, remove the sediment bowl, if so
equipped, from beneath the fuel tank and clean
out any accumulated dirt and water.
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.
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.
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.
BEARINGS
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
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.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
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.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
COMMUTATOR AND BRUSHES
------------------------------------------------------------------------
See additional warning information at
WARNING
front of this operator’s manual.
-----------------------------------------------------------
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.
------------------------------------------------------------------------
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.
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.
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 KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
D-2
D-2
MAINTENANCE
Replace brushes when they wear within 1/4”(3.5mm)
of the pigtail. A complete set of replacement brushes
should be kept on hand. Lincoln brushes have a
curved face to fit the commutator. Have an 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.
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.
------------------------------------------------------------------------
Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
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:
IDLER MAINTENANCE
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)
CAUTION
Before doing electrical work, disconnect the bat-
tery.
------------------------------------------------------------------------
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.
Air Bleeding
Valve
1. Proper operation of the idler requires good
grounding of the Engine Control Unit, current
sensing printed circuit board and battery.
FIGURE D.1
2. If desired, the welder can be used without automat-
ic idling by setting the “Idler” switch to the “High”
position.
2. Turn the engine by pressing the start button until
the engine runs smoothly (this should take approxi-
mately 10 seconds).
NAMEPLATES
3. Fully close the air bleeding valve by turning it
clockwise.
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.
Contact your Kubota Engine repair facility if problems
persist.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
D-3
D-3
MAINTENANCE
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE (50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 150 HOURS OR 4 MONTHS
EVERY 30O HOURS OR 9 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 500 HOURS OR 15 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM
Coolant level
TYPE OR QUANTITY
I
I
I
Concentration of antifreeze
R Coolant (NOTE 3)
50/50 Water/Ethylene Glycol
9.5 qrts., 9.0L
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
R
R
R
8.0 qrts., 7.6L (including filter)
R
C
Drain water separator & fuel strainer
Fuel filter canister
R
R
I
I
Tension of alternator drive belt
Alternator drive belt wear
Alternator drive belt
R
Kubota # 17480-97010
C
Air filter (earlier check may be req'd)
Air filter element
Donaldson # P821575
I
I
I
Valve clearances
Intake .0071"-.0086", Exhaust .0071"-.0086"
Electrical systems
All nuts and bolts for tightness
Leaks or engine damage
Battery
I
I
I = Inspect
Notes:
C = Clean
R = Replace
(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.
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.
If necessary use shorter periods.
S25833
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 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.
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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Machine fails to hold the output 1. Rough or dirty commutator.
(heat) consistently.
2. Brushes may be worn down to
Limit.
3. Field circuit may have variable
resistance connection or inter-
mittent open circuit due to
loose connection or broken
wire.
4. Electrode lead or work lead
connection may be poor.
5. Wrong grade of brushes may
have been installed on gener-
ator.
6. Field rheostat may be making
poor contact and overheating.
Welder starts but fails to generate 1. Generator or exciter brushes
current.
may be loose or missing.
2. Exciter may not be operating.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
3. Field circuit of generator or
exciter may be open
4. Exciter may have lost excita-
tion.
5. Series field and armature cir-
cuit may be open-circuited.
Welding arc is loud and spatters 1. Current setting may be too
excessively.
high.
2. Polarity may be wrong.
Welding current too great or too 1. Exciter output low causing low
small compared to indication on
the dial.
output compared to dial indica-
tion.
2. Operating speed too low or too
high.
Arc continuously pops out.
1. “Current Range Selector”
switch may be set at an inter-
mediate position.
Flashing the exciter field consists of passing current through the fields using an external source of 6 to 125 volts of DC power
from a storage battery or DC generator. If using a DC generator, keep the generator turned off except when actually applying
the flashing current. To flash the fields:
1. Turn the welder off. Raise one exciter brush off the commutator.
2. On Lincoln welders, attach the positive lead from the external DC source to the right hand brushholder.
3. Carefully holding an insulated section of the negative lead from the DC source, touch its lug or clamp to the left hand
brushholder for five seconds. Pull it away quickly to minimize arcing.
Remove the lead from the right hand brushholder, replace the brush on the commutator, start the welder and the generator
voltage should build up.
CAUTION
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Engine does not start.
1.
2.
3.
4.
Lack of fuel.
Air mixed in the fuel system.
Clogged fuel filter.
Irregular and faulty fuel supply
(Injector pump trouble).
5.
6.
7.
8.
1.
Glow plug not heated.
Clogged air cleaner.
No compression.
Engine protection light is ON.
Engine does not turn over.
Faulty Ignition switch and or
Injector pump solenoid.
2.
3.
Insufficient charging or com-
plete discharge of the battery.
If all recommended possible areas
Improper viscosity of the lubri- of misadjustment have been
cating oil.
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Irregular running of the engine.
1.
2.
Air mixed in the fuel system.
Uneven fuel injection (Faulty
fuel injector pump).
3.
4.
5.
Clogged fuel filter.
Defective governor.
Engine itself defective.
Lack of fuel in the fuel tank.
Clogged fuel filter.
Engine stops during operation and 1.
the Engine Protection light does
not turn on.
2.
3.
4.
Air mixed in the fuel system.
Faulty function of the engine.
Engine stops during operation and See Light Code Diagnoses
the Engine Protection light does Attached.
turn on.
CAUTION
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
LIGHT CODE
FAILURE DETECTED
POSSIBLE CAUSE - CORRECTIVE MEASURE
LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM)
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND
ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY
PLUNGER PULLS IN WHEN ENERGIZED
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK"
STUD IS OPEN WHEN ENGINE IS RUNNING
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE
GROUNDED - CHECK
LONG 1, SHORT 3 "L" TERMINAL IS GROUNDED ON ALTERNATOR
FOR 1 SECOND
BROKEN OR LOOSE BELT
LEAD TO "L" TERMINAL ON ALTERNATOR MAYBE
SHORTED TO GROUND- CHECK
FAULTY ALTERNATOR - CHECK
LONG 1, SHORT 4 HIGH WATER TEMPERATURE DETECTED
FOR 1 SECOND
AMOUNT OR QUALITY OF COOLANT INCORRECT
- CHECK
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT
"WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE
GROUNDED - CHECK
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT 1 0 RPM IS DETECTED AND 12V IS DETECTED
FROM "L" TERMINAL ON ALTERNATOR
FAULTY RPM SENSOR-CHECK FOR GOOD CONNECTION
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD
TO RPM SENSOR FROM ECU
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
FAULTY ACTUATOR - CHECK FOR PROPER COIL
RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED
- CHECK
LONG 2, SHORT 3 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT 4 -50C WATER TEMPERATURE DETECTED
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR
PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN
- CHECK FOR CONTINUITY
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR
PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE
GROUNDED - CHECK
LONG 2, SHORT 6 0 VOLTS DETECTED FROM "L" TERMINAL ON
ALTERNATOR FOR 1 SECOND
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN
- CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
FAULTY ALTERNATOR - CHECK
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
INCORRECT BATTERY - INSPECT
FAULTY ALTERNATOR - CHECK
LONG 2, SHORT 8 LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
ACTUATOR SENSED BY ECU
FAULTY ECU -CHECK FOR 12 VOLTS ON LEADS TO RPM
SENSOR AND ACTUATOR FROM ECU
CAUTION
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
White or Blue Smoke.
1. Excess engine oil.
2. Too low viscosity of the
engine oil.
3. Faulty injection timing.
Dark Grey Smoke.
1. Unsuitable fuel.
2. Excess injection.
3. Faulty function of the engine.
4. Overloading.
5. Clogged air cleaner.
Faulty Charging.
1. Loose fan belt.
2. Faulty wiring.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
3. Faulty battery.
4. Worn out alternator brush.
Starter Motor does not run.
1. Loose or damaged wiring.
2. Drained voltage from battery.
3. Damaged starter motor
(including solenoid).
Engine Protection Light not com- 1. Broken Light Bulb.
ing on.
2. Faulty light wiring.
3. Faulty Engine Control Unit.
CAUTION
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
E-6
E-6
TROUBLESHOOTING
ELECTRONIC IDLER TROUBLESHOOTING GUIDE
With Idler Control Switch in the Auto Position,
Engine Will Not Return to Low Idle in Approximately 15 Seconds
After Welding and Auxiliary Loads are Removed
Set Idler Control Switch
to the Auto Position
Check for Continuity through Idler
Control Switch
Open
Closed
Check Voltage across
Idler Control switch
Replace Idler
Control Switch
12 VDC
0 VDC
Contact Kubota
Engine Repair
Facility
Replace current
Sensing PCB
CAUTION
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
E-7
E-7
TROUBLESHOOTING
ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE
With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When:
The Arc is Struck
Both
Auxiliary Load
1. Load too small. Try load
above 100 Watts.
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.
3. Check voltage across idler control
switch.
12V
0V
Replace Current
Sensing PCB
Contact Kubota
Engine Repair
Facility.
CAUTION
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.
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
F-1
F-1
DIAGRAMS
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
F-2
F-2
DIAGRAMS
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
F-3
F-3
DIAGRAMS
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
F-4
F-4
DIAGRAMS
K2464- REMOTE
1
CONT
ROL
IRING /CONNECT
AGRAM
ION DI
W
X
Y
G
B
W
CV “WIRE” CONTROL POT
CCW
RESISTORS
CC “STICK” CONTROL
BLUE
ORANGE
RED
CABLE CONNECTION TABLE
LEAD COLOR
PIN
E
RED
F
G
C
ORANGE
BLUE
REMOTE CONTROL BOX
WHITE JUMPER
CONNECT TO CASE
PER
WHITE JUM
D
A
S26097
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
F-5
F-5
DIMENSION PRINT
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTES
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTES
PIPELINER® 200D KUBOTA
Download from Www.Somanuals.com. All Manuals Search And Download.
G Do not touch electrically live parts or
electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
G Keep flammable materials away.
G Wear eye, ear and body protection.
WARNING
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible
G Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
G Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
G Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
G Gardez à l’écart de tout matériel
inflammable.
G Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
G Isolez-vous du travail et de la terre.
German
G Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Download from Www.Somanuals.com. All Manuals Search And Download.
G Keep your head out of fumes.
G Use ventilation or exhaust to
remove fumes from breathing zone.
G Turn power off before servicing.
G Do not operate with panel open or
guards off.
WARNING
Spanish
G Los humos fuera de la zona de res-
piración.
G Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
G Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
G No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
tien.
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
G Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
G Vermeiden Sie das Einatmen von
Schweibrauch!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
G Não opere com as tampas removidas.
G Desligue a corrente antes de fazer
serviço.
G Mantenha-se afastado das partes
moventes.
G Não opere com os paineis abertos
ou guardas removidas.
G Mantenha seu rosto da fumaça.
G Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
G Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Download from Www.Somanuals.com. All Manuals Search And Download.
• World's Leader in Welding and Cutting Products •
• 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
Download from Www.Somanuals.com. All Manuals Search And Download.
|