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PIPELINER 200
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part.
And,
most
importantly, think before you act
and be careful.
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Summary of Contents for Lincoln Electric PIPELINER 200
- Page 1 RETURN TO MAIN MENU ® PIPELINER 200 Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. And,...
- Page 6 RETURN TO MAIN MENU...
- Page 22 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...
- Page 42 EVERY DAY OR EVERY 8 HOURS FIRST SERVICE-(20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Concentration of antifreeze Coolant (NOTE 3)
- Page 60 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE-(50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 600 HOURS OR 12 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Concentration of antifreeze Radiator for contamination or blockage Coolant (NOTE 3) Engine oil level (NOTE 1)
- Page 63 ENGINE FROM CURRENT ENGINE PROTECTION HOUR SENSING P.C. BOARD LAMP METER IDLER SWITCH ENGINE CONTROL UNIT (ECU) CONTROL ENG. IGNITION GAUGE TEMP. CIRCUITRY GAUGE ENGINE ENGINE TEMP. SPEED SPEED SENSOR ACTUATOR SENSOR SWITCH SENSOR SWITCH ENGINE STARTER IGNITION MOTOR SWITCH KUBOTA COUPLED TO START...
- Page 64 ENGINE FROM CURRENT ENGINE PROTECTION HOUR SENSING P.C. BOARD LAMP METER IDLER SWITCH ENGINE CONTROL UNIT (ECU) CONTROL ENG. IGNITION GAUGE TEMP. CIRCUITRY GAUGE ENGINE ENGINE TEMP. SPEED SPEED SENSOR ACTUATOR SENSOR SWITCH SENSOR SWITCH ENGINE STARTER IGNITION MOTOR SWITCH KUBOTA COUPLED TO START...
- Page 65 ENGINE FROM CURRENT ENGINE PROTECTION HOUR LAMP SENSING P.C. BOARD METER IDLER SWITCH ENGINE CONTROL UNIT (ECU) CONTROL GAUGE TEMP. GAUGE ENGINE ENGINE TEMP. SPEED SPEED SENSOR ACTUATOR SENSOR SWITCH SENSOR SWITCH STARTER MOTOR KUBOTA START RELAY DIESEL ENGINE ENGINE IGNITION SWITCH ENGINE...
- Page 66 ENGINE ENGINE FROM CURRENT FAILURE HOUR LAMP SENSING P.C. BOARD METER IDLER IGNITION IDLER/ENGINE SWITCH SWITCH PROTECTION P.C. BOARD BATTERY TEMP. GAUGE GAUGE FUEL PUMP FUEL SOLENOID TEMP. SENSOR SWITCH SENSOR STARTER SWITCH ENGINE MOTOR IDLER SOLENOID PERKINS DIESEL ENGINE ENGINE COUPLED TO ALTERNATOR...
- Page 67 ENGINE ENGINE FAILURE HOUR LAMP METER IDLER SWITCH ZENITH THROTTLE FUEL INJECTORS BODY CONTROLLER FUEL CONTROL PUMP THROTTLE PLATE MOTOR ENG. IGNITION WATER GAUGE CIRCUITRY GAUGE WATER & PRESSURE & AIR TEMP. WATER TEMP. SENSOR SENSOR SENSOR ENGINE IGNITION SWITCH G.M.
- Page 68 ENGINE CONTROL/PROTECTION MODULE SELECTOR SWITCH 90 Min. SERIES RESIDUAL COILS MAGNETISM SHUNT FIELD GENERATOR MECHANICAL ARMATURE EXCITER COUPLING ARMATURE SHAFT ARMATURE SERIES FIELD SHUNT INTERPOLE FIELD COILS COILS GENERATOR FIELD CONTROL NEGATIVE OUTPUT Current TERMINAL Sensing P.C. Board 15 AMP FUSE RECEPTACLE 120VDC...
- Page 69 SHUNT FIELD WINDINGS MAGNETIC FIELD GENERATOR MECHANICAL COUPLING ARMATURE MAGNETIC FIELD SHUNT FIELD WINDINGS DC CURRENT BRUSH ARMATURE SHAFT BRUSH DC CURRENT...
- Page 84 SERIES COIL CONNECTION POINT (NEGATIVE) POSITIVE...
- Page 85 EXITER COVER CHECK VOLTAGE AT BRUSH HOLDERS HERE (RIGHT SIDE IS +) WARRANTY...
- Page 86 WARRANTY WHITE FLEX LEAD SMALL FLEX LEAD SOLID LEAD (continued) RED LEAD - EXCITER ARMATURE EXCITER SERIES FIELD EXCITER SHUNT FIELD 120 VOLTS...
- Page 88 (continued) QUICK CONNECT LEADS...
- Page 90 (continued) PLUG P10...
- Page 91 (continued) PIN 3 PIN 5...
- Page 94 (continued) EXITER COVER...
- Page 95 TO NEGATIVE BATTERY TERMINAL (continued) WARRANTY RAISE EXCITER BRUSH OFF COMMUTATOR TO POSITIVE BATTERY TERMINAL...
- Page 98 BACK OF ALTERNATOR Alternator Output Leads...
- Page 100 TEMP SW. / SENDER S25162 1/2-14 NPT 1/4" SPADE TERMINAL OIL SWITCH / SENDER .19 .03 3/16" SPADE TERMINAL S17026-3...
- Page 104 BOLT / NUT (4) “L” DOOR HOOKS (4)
- Page 108 BLOWER PADDLE MARK...
- Page 110 IDLER ADJUSTMENT LOCK NUT BALL JOINT IDLER ROD...
- Page 116 POLE PIECE BOLTS (4) EXITER FRAME BRUSH HOLDER ARMATURE ASSEMBLY (2) SLEEVE COLLAR FLAT WASHER ARMATURE LOCKING NUT EXITER COVER...
- Page 120 NEGATIVE BATTERY CABLE...
- Page 121 BOLT / NUT (4) 'L' DOOR HOOKS (4)
- Page 122 BOLTS / NUTS / WASHERS (4) FUEL LINE FUEL TANK FUEL BOWL RAILS...
- Page 123 SELECTOR SWITCH TERMINAL LEAD (5) POSITIVE OUTPUT TERMINAL AND LEAD...
- Page 124 LOOSEN CHOKE HERE CABLE...
- Page 125 IDLER PC BOARD IDLER SWITCH TO IDLER SWITCH IGNITION SWITCH LEADS TO AMMETER START BUTTON SHUNT LEADS DC RECEPTACLE QUICK DISCONNECT...
- Page 126 BOLTS / NUTS / WASHERS (2) MIDDLE SCREW (1) BASE MOUNTING BOLTS (4)
- Page 127 CLAMPING BOLT BRUSH BRACKET REMOVE (2) NUTS, WASHERS, AND SCREWS WRAP- AROUND COVER BRUSHES (8) BRUSH BRACKET...
- Page 128 MAIN GENERATOR FEET (2) REMOVE MOUNTING NUTS, WASHERS, AND BOL TS SLING ENGINE / GENERATOR MOUNTING HOLES...
- Page 129 Refer to needed.
- Page 132 SLING BLOWER PADDLE MOUNTING BOLTS / LOCK WASHERS (8) Refer to Figure F.28...
- Page 136 602B 600B 602A RHEOSTAT 600A SELECTOR SWITCH 610B GENERATOR 5 4 3 2 1 WELDER LEAD BLOCK CURRENT SENSOR NEGATIVE POSITIVE (CC-) (CC+) & (CV+ WITH W.F.M.) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5". CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
- Page 137 600A SELECTOR SWITCH SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION. GENERATOR 610B 5 4 3 2 1 WELDER LEAD BLOCK CURRENT SENSOR NEGATIVE POSITIVE (CC-) (CC+) & (CV+ WITH W.F.M.) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
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Page 138: Electrical Diagrams
WIRING DIAGRAM - CODE 10929 - (M20056) GLOW PLUGS ENGINE HOUR GLOW METER START PLUG STARTING MOTOR GROUND GROUND TO BASE ENGINE K924-5 REMOTE CONTROL (OPTIONAL) RESISTORS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ELECTRICAL DIAGRAMS PIPELINER 200D WIRING DIAGRAM EXCITER BRUSHES SHOWN AS... - Page 139 WIRING DIAGRAM - CODE 11114, 11316 - (M20464) GLOW PLUGS START START RELAY GLOW PLUG BATTERY GROUND BASE RESISTORS REMOTE CONTOL POTENTIOMETER BOX NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ELECTRICAL DIAGRAMS PIPELINER 200D WIRING DIAGRAM ENGINE CONTROL UNIT CONNECTOR DETAIL...
- Page 140 WIRING DIAGRAM - CODE 11471 - (M21564) GLOW PLUGS START GLOW PLUG BATTERY GROUND BASE RESISTORS REMOTE CONTOL POTENTIOMETER BOX NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ELECTRICAL DIAGRAMS PIPELINER 200D WIRING DIAGRAM ENGINE CONTROL UNIT CONNECTOR DETAIL...
- Page 141 SCHEMATIC -COMPLETE MACHINE - CODE 10929 - (L12020) L12020 ENGINEERING CONTROLLED MANUFACTURER: J2 CONNECTOR IS NOT USED ON THIS MACHINE RED ENGINE PROTECTION LIGHT 12 VOLT - NORMALLY OFF INJECTION PUMP SOLENOID TYPICAL CURRENT DRAW IS .98 AMPS FUEL PUMP TYPICAL CURRENT DRAW IS .56 AMPS HOUR METER...
- Page 142 SCHEMATIC - COMPLETE MACHINE - CODE 11114, 11316 - (L12362) L12362 ENGINEERING CONTROLLED MANUFACTURER: ENGINE RATED VOLTAGE: 12V SPEED RATED CURRENT: 22mA MAX SENSOR BACK, RIGHT SIDE OF ENGINE SENSOR OPERATION: WATER F -> 18.80 kOHMS TEMP. F -> 1.14 kOHMS SENSOR F ->...
- Page 143 SCHEMATIC - COMPLETE MACHINE - CODE 11471 - (L13350) L13350 ENGINEERING CONTROLLED MANUFACTURER: ENGINE RATED VOLTAGE: 12V SPEED RATED CURRENT: 22mA MAX SENSOR BACK, RIGHT SIDE OF ENGINE SENSOR OPERATION: WATER -> 18.80 kOHMS TEMP. F -> 1.14 kOHMS SENSOR F ->...
- Page 144 G-10 SCHEMATIC - CURRENT SENSE PC BOARD - CODE 10929,11114, 11316, 11471 - (S25973) S25973 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 ±...
- Page 145 G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - IDLER/ENGINE SHUTDOWN - CODE 10929 (L10826) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. PIPELINER® 200...