Lincoln Electric PIPELINER 200 Service Manual page 142

G-8
SCHEMATIC - COMPLETE MACHINE - CODE 11114, 11316 - (L12362)
ELECTRICAL DIAGRAMS
CHANGE DETAIL: Released A.02 from X
L12362 ENGINEERING CONTROLLED
No
MANUFACTURER:
12 VOLT SUPPLY
94 20
ENGINE
RATED VOLTAGE: 12V
ENGINE CONTROL UNIT (ECU)
SPEED
93 17
RATED CURRENT: 22mA MAX
SENSOR LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
BACK, RIGHT 60A
RATED VOLTAGE: 12V
SIDE OF ENGINE
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
69 13
SENSOR OPERATION:
WATER
-4 F -> 18.80 kOHMS
v
TEMP.
104 F -> 1.14 kOHMS
v
SENSOR
212 F -> .16 kOHMS
v
60
BACK, LEFT
SIDE OF ENGINE
RATED VOLTAGE: 12V 1
RATED CURRENT: 2A 10
COIL RESISTENCE: 57 34
18
2.8 +/- .28 OHMS AT 20 v C
26
ENERGIZED FOR RUN 12 VOLT
ACTUATOR
DE-ENERGIZED FOR STOP
SUPPLY
ACTUATOR CONTROLS RPM BACK, RIGHT
MECHANICAL STOP WILL SHUT
SIDE OF ENGINE
56 18
DOWN THE ENGINE AT 115%
OF RATED SPEED.
ECU CONNECTOR DETAIL
ENGINE
COLOR: RED
PROTECTION
61 9
12 VOLT
LIGHT
THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE
NORMALLY OFF CENTER OF
841A PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT
CONTROL PANEL
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT
+ DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE
HOUR METER 58 6
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
CENTER OF
CONTROL PANEL 31 1 19
CONNECT TO
841B
60F 60E GROUND FOR
800RPM
844A OPEN LEAD IS WIRE-TIED INSIDE THE
HARNESS BEHIND CONTROL PANEL
GND-B
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
LOCATED BEHIND UPPER LEFT
PORTION OF CONTROL PANEL
841 844
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
12 VOLT SUPPLY
842
LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE
LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM) ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND 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
BROKEN OR LOOSE BELT - INSPECT
"L" TERMINAL IS GROUNDED ON ALTERNATOR
LONG 1, SHORT 3 LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FOR 1 SECOND
FAULTY ALTERNATOR - CHECK
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
HIGH WATER TEMPERATURE DETECTED FOR 1
LONG 1, SHORT 4 FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
SECOND
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
0 RPM IS DETECTED AND 12V IS DETECTED FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
LONG 2, SHORT 1
FROM "L" TERMINAL ON ALTERNATOR FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
0 VOLTS DETECTED FROM "L" TERMINAL ON
LONG 2, SHORT 6 BROKEN OR LOOSE BELT - INSPECT
ALTERNATOR FOR 1 SECOND
FAULTY ALTERNATOR - CHECK
INCORRECT BATTERY - INSPECT
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
FAULTY ALTERNATOR - CHECK
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
LONG 2, SHORT 8
ACTUATOR SENSED BY ECU FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
JUMPER PLUG IS BEHIND LOW ER
LOW ER RIGHT OFCONTROL PANEL
RIGHTSIDE OFCONTROL PANEL
RPM CONTROL POTENTIOMETER
11 87 1
10,000 +/- 1,000 OHMS MAX
TURN POT COUNTERCLOCKWISE TO
2 86 2
REDUCE RESISTANCE AND SUBSEQUENTLY
CCW
REDUCE RPM BY UP TO 150RPM
3 88
3
BACK, LEFT SIDE OF ENGINE
4
ALTERNATOR
40 AMP / 12 VOLT
26 64
SENSES ALTERNATOR OUTPUT
FLASHES ALTERNATOR
212E
16 51B
IGNITION
SWITCH
9 15
212D
SHOWN IN "OFF"
17
POSITION
25
BACK, LEFT SIDE OF ENGINE
212A
34
S I
28 43 841B
44
W TEMPERATURE
G G
GAUGE
LOW ER LEFT OF
TEMPERATURE SWITCH / SENDER
212B CONTROL PANEL
SWITCH CLOSES
SENDER OPERATION:
AT 230 +/-6 F
v v 140 v F -> 134+/-13.5 OHMS
194 v F -> 51.2+/-4.3 OHMS SENDER IS APPROX.
212 F -> 38.5+/-3 OHMS 500 OHMS AT 70
v
FRONT, LEFT SIDE OFENGINE
S I
OIL PRESSURE
27 54 200
GAUGE
WK G
G
LOW ER LEFT OF
CONTROL PANEL
OIL PRESSURE SWITCH / SENDER
30 32 7 12
SWITCH CLOSES SENDER OPERATION:
AT 6+/-2 PSI 0 PSI -> 10+/-5 OHMS
CONNECT TO
40PSI -> 105+/-5 OHMS
70A 70B GROUND FOR
80 PSI -> 187+/-5 OHMS
1600RPM, LEAVE
UNCONNECTED 52B
70C
FOR 1800RPM 55
DC EXCITER
FDW-5M EXCITER COIL:
SHUNT COIL WINDINGS ARE 65+/-1.5 OHMS EACH
SHUNT FIELD
DC EXCITER USES RESIDUAL
SERIES COIL WINDINGS ARE .143 +/-.005 OHMS EACH
MAGNETISM TO FLASH
-
+
SERIES FIELD BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
610C
610B
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN SAME (CURRENT
CURRENT SENSING PC BOARD
FLOW) DIRECTION AS SHOWN
SCHEMATIC S25973
LOW ER LEFT OFCONTROL PANEL
J3-4
DRIVER 610D
J3-1
CIRCUITS
FUSE
J3-3
15 AMP
J3-2
3 TURNS
67B
SELECTOR SWITCH
_
+
67A
NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL
TYPICAL OCV (WARM MACHINE):
88-98 VOLTS AT MAX RHEOSTAT
47-60 VOLTS AT MIN RHEOSTAT
UNDER LEFT DOOR
PROPRIETARY & CONFIDENTIAL:
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
K924-5 REMOTE CONTROL
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG
GLOW PLUG SWITCH
BUTTON
53
GLOW PLUGS
51C
TYPICAL CURRENT
DRAW IS 40 AMPS
L
IG
B
-40 TO 40 AMPS
AMMETER
51 BACK, BOTTOM
-
OF MACHINE
51A 50 STARTER +
+
SOLENOID
BATTERY
STARTER 12.6 VOLTS MIN
64+/-6.4 OHMS MAX
MOTOR AT REST
50A
14-14.5 VOLTS
WHILE RUNNING
START
BUTTON
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
62
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
F
v SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
212C
DOWN DUE TO A FAULT (EVEN IF THAT CONDITION
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF FUEL), THE IGNITION SWITCH WILL NEED TO BE
52A
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
STARTER
RELAY
WIRE-TIED TO HARNESS
BEHIND CONTROL PANEL
THE P10 PLUG IS ONLY ON UNITS WITHOUT
P10
THE WIRE FEED MODULE. THE WIRE FEED
MODULE HAS A HARNESS THAT PLUGS 12 11 10 9 8 7 6 5 4 3 2 1
DIRECTLY INTO J5.
J5
610
RHEOSTAT
64+/-6.4 OHMS MAX
CCW
730A
602B
DC AUXILIARY
41
RECEPTACLE 602A
42
GND-T
J8
5 4 6 3 1 2
P9
JUMPER PLUG IS
WIRE-TIED UP BEHIND
G
602
LOCAL / REMOTE
Y SWITCH ON RIGHT
720C 720A 720B
X SIDE OF MACHINE
W
N
REMOTE
RECEPTACLE
LOCAL / REMOTE
GENERATOR LEAD BLOCK
SWITCH
SHOWN AS VIEWED WITH
ENGINE IN THIS DIRECTION 730B
SHOWN IN LOCAL
POSITION N
SERIES FIELD
-
+
SHUNT
90-MIN
FJW-5AR COIL PAIR:
FIELD
130-80 + -
22.5+/-.5 OHMS EACH
190-120
240-160
INTERPOLE
220-MAX
COILS
WELDING
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
GENERATOR
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
REFERENCE: PIPELINER 200D (KUBOTA V2203M)
DESIGN INFORMATION EQUIPMENT TYPE:
DM L12020
DRAWN BY:
MACHINE SCHEMATIC
SUBJECT:
t ENGINEER: J. STAPP SCALE:
MATERIAL APPROVAL PROJECT
UF
NA 08/04/2004
APPROVED: DISPOSITION: DATE: NUMBER:
G-8
(OPTIONAL)
REMOTE CONTROL PLUG
G
Y
X
W 25+/-1.25 OHMS EACH
CCW
RHEOSTAT
REMOTE CONTROL BOX
FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
JUMPER PLUG IS
WIRE-TIED UP BEHIND
LOCAL / REMOTE
SWITCH ON RIGHT
SIDE OF MACHINE (AS
VIEW ED FROM
CONTROL PANEL)
U
U
COMPONENT VALUE UNITS:
LEAD COLOR CODE:
B-BLACK OR GRAY
CAPACITOR: MFD/VOLTS
G-GREEN
RESISTOR: OHMS/WATTS
O-ORANGE
R-RED OR PINK
CONNECTOR PIN NUMBERS:
U-BLUE
W-WHITE
EX. 12 PIN CONNECTOR
Y-YELLOW
1 2 6
LABELS:
COMMON
7 12
FRAME GROUND
LATCH
EARTH GROUND
VIEW OF CONNECTOR ON PC BOARD
1 1
PAGE ___ OF ___
DOCUMENT
DOCUMENT
REVISION:
NUMBER:
L12362 A
CRM35581
PIPELINER® 200