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Lincoln Electric 11498 Welder User Manual

1. 01 SET AIIM HA Se ETEA il gl asl y d gll olg qul AI agi L LINCOLN 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
2. PIPELINER 2000 LINCOLN N Jequunu SDOO 1u udinb e 1USUJJBdS 20S ou O 1NA s eui y SISUBd y Jo euo uo y LL SDISUI pejsed SI epoo e oul siy Aq SSUIUOBUU 104 eq jou Aew 1 AIUO JO SI 5141 310 VELZCIN REN SNOILO3NNOO 3S3H L NHHM 3B1VTnSNI G3193NNOO STVNIWH 1 ONINNNE 38 LON LSNW 3NIHOVIN daa S3HIM 2209 AOW H WAM ddInO dl AH SSV 1V 1SOWH3HL 052 DAN OL L03NNOO WNIINH3L LNdLNO d 1 AOILN 10d 8570 OL LOANNOO E 101 00 10Wdd __ O3N o SVNWHL 114100 i 3343 SOd oJ DAN 9 SOd OL LOANNOO NN Sd DOIT 3NIHOVN NO HOLO3NNOO OL WM NO LOANNOO d 1 OIIN 10d t HOLO3NNOO WOH Did ET 3AOW3H 3NIHOVIN NO OHLNOO 401 9fT Td IYNOILdO JINGOW 0334 SHIM 1VNOILdO TOH LNOO 1OW H S v26M NMOHS SV NOLLO3HIQ MO14 N HHn9 ANS NI HOSN3S N dnO S391V9 ANIONS NHL 38 LSNW SdV 1 S
3. e 3544 2452 84 xc uu YRA e 2x9 AAS ASA OAR JM W jas la oaa Y pad slay d ril gs DE Y jo pg Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e e 18 9 Z VAM i TS BEL IER 248 42 AIX nig ALI Aal pu e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und KOr perschutz Use prote o para a vista ouvido e corpo e RER H X 5466 SIRI R e 119 Sal sare diii due de Lily ques cl gal e A READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS AND THE CONSUMABLES 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
4. jenueui siy Aq je 104 eq jou 10 SI eil 310 v9SLcIN SNOILOANNOO S HT 9NIMVIN ONINNNE 38 LON LSNW 3NIHOVIN geg IVISONWHSHI div 0S2 HAN OL 193NNOO Sisi ESOS xog CHE QV3TAAV3HZ Nd f VNIWH 1 LAdLNO _ AO AIVSN ndoW Oval ANH 8 BN gl S NINEHIT 178170 I SHO SIS d Q333 deme 809 OIN SOd OLLOSNNOO Sd 9019 NIHOVW NO 97 HOLO3NNOO OL NO LOANNOO H 1 WOIN 1Od 9 HOLO3NNOO OH 014 OT 3AOINSH 3NIHOVW NO TOHLNO9 31ON3t HOS Td SINGOW A334 3HIM IVNOILdO 1OW H 9 7267 NMOHS SV NOLLO3HIQ MO13 IWYS NI HOSN3S S DTIV9 ANIONS THH1 q31noti 38 LSNW 5737 SSSHL HOLIMS ual YVAN M3H9S GNNOYD 3NION3 3578 CAM HLIM A0 8 90 99 278 49 _ OL 217 LOL ANWLISOd SALLWOSN pre j 9 309 729 V09 09 OJ pet E 69 _ HOSN3S HOSN3S SNENL I 48995 dl ANIONS H31vVM SIHL NI 3NION3 3o9nvo SV NMOHS 3unsSdud 90018 dV 1 HOIVH N 5 9 9 HHIHMWV NOLLISOd TVOOTNI HOLIMS NS 002 O 79 NMOHS TOHL
5. HR D 1 Commutator and Brushes nana D 1 Idler Ma int Nane uu uuu D 2 NAMEPIALSS 22 tials D 2 Purging Air from Fuel System uiia iiec e veer de D 2 Engine Service Chart issues D 3 Tr oubleshooti g uuu Section E Safety Precauti ns pe dress ie a a taire E 1 Welder Troubleshooting a E 2 Engine Troubleshooting Guide E 3 E 4 E 5 Electronic Idler Troubleshooting Guide E 6 E 7 Diagrams M Section F Wiring Dagr UR F 1 F 2 F 3 F 4 Dimension PEE esner cre rae printed eco ETEEN Ha ERE Te diee ed sed es F 5 Parts RT 504 Series A INSTALLATION 1 TECHNICAL SPECIFICATIONS PIPELINER 2000 KUBOTA INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities System 4 Cylinder 4 Cycle 148 53 cu in 12VDC battery Fuel 15 gal Naturally Aspirated 2 43 Itrs Group 45 650 57 L Kubota Water Cooled High Idle 1600 cold crank amps V2403M Diesel Engine Low Idle 1400 Bore x Stroke 1 4 KW Starter Oil 10 04 Qts Tier 4 interim Cast Iron Cylinder Full Load 1600 40 A Alternator 9 5L Compliant Block Crankcase 3 43 x 4 03 w built in reg Coolant 9 5 Qts 27 8HP 91600 RPM 9 0L RATED OUTPUT 104 F 40 C WELDER DESCRIPTION RATED DC OUTP
6. 8 58606 9917 Ge 8 1OH ONILNOW 9101 9 10L 1OH DNILNOW Qnis 99 oor 00 ans ged SZ 6r ni S8 276 ZELE WN 7 099 L SSLL 00 9Z ocv 1 C a I 1 27271 00 89 PIPELINER 200D KUBOTA LINCOLN NOTES PIPELINER 2000 KUBOTA LINCOLN NOTES PIPELINER 2000 KUBOTA LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra e
7. AVE HO HO 78 8 3009 40109 QV31 TANVd OU INCO OH MIA SV NMOHS S3HShH8 H31IOX3 SS3NHVH OLNI GALL ANY N3dO 1431 SI V0Z QV31 310N 11 134 335 LINN TO8LNOO NIBN OL GALOSNNOO SdV 1 UNO OH SV NWOHS SLNANOdWOO T3NVd TOHLNOO 0 95 3NION3 vo 409 Boynloy p Fog 98 TANVd TOHLNOO SS3NHVH OL q 1 HIA 18 88 ges 8G GEI Soma MOTD E IIV L30 HOLO3NNOO LINN TOH LNOO 3NION3 Vv9LL 3803 401 INVH9VIG H3NI T3dld PIPELINER 2000 KUBOTA LINCOLN F 4 DIAGRAMS F 4 K2464 1 REMOTE CONTROL WIRING CONNECTION DIAGRAM C CV WIRE CONTROL POT CW a H em CC STICK CONTROL sue ORANGE REMOTE CONTROL d CONNECT TO CASE CABLE CONNECTION TABLE CONNECTION TABLE PIN PIN LEADCOLOR WHITE JUMPER WHITE JUMPER A S26097 PIPELINER 2000 KUBOTA LINCOLN DIMENSION PRINT F 5 F 5 21 992015 lov 27244 2906 6697 0981 886601 6 Ot II 9 609 00 Z SATOH ONILNNOW 1IVd1 Cv 1 S ON 1304 NO 109 3NION3 NI H31VM ANY 110 ALIAVH9 dO H31N39 SILON be 89 90 0 76 91 8901 gg
8. A 5 INSTALLATION Battery Charging A 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 2 b Using 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 Th
9. 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 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 B AN LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED CHECK LONG 2 SHORT 6 0 VOLTS DETECTED FROM L TERMINAL ON LEAD TO L TERMINAL ON ALTERNATOR MAY BE OPEN ALTERNATOR FOR 1 SECOND LONG 2 SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR FAULTY ALTERNATOR CHECK LONG 2 SHORT 8 LESS THAN 4 VOLTS TO RPM SENSOR AND OR FAULTY ECU CHECK FOR 12 VOLTS ON LEADS TO RPM ACTUATOR SENSED BY ECU 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 LINCOLN E 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual White or Blue Smoke Excess engine oil Too low viscosity of the engine oil Faulty injection timing Dark Grey Smoke Unsuitable fuel Excess injection Faulty
10. Pre Operation Installation A 3 Safety Precautions xu u RR EL PUER sn ia nen ane A 3 Exhaust Spark Arrester seride nienn ianei neniani nenii aiea eao aidi A 3 L cat n acirc rnei NE REAA Machine Groundimg sus A 3 LE 3 THAN e A 4 Polarity Control and Cable Sizes 4 Pre Operation Service A 4 ON A 4 I tes cee A 4 Cooling 4 Battery Chargihg ERU A 5 jer mee c Section B 2 ii 1 Starting The Kubota V2403M Engine Cold Weather Starting B 1 High Altitude Operation ease Ree bonae N B 1 Stopping the engine sis B 1 ne B 1 Welder Operation EE B 2 Duty E B 2 Control of Welding Current eene B 2 ls al iun B 3 Auxiliary EE B 3 Fuel Consumption Data sine or en pev ee A B 3 AGG6888S0OF I 88 u Section C Optional Features Field Installed C 1 Wire Feed Options oeste in andi C 1 clchrap L Section D Safety Precautions AAA D 1 G n ral INStruCtiOns Ri D 1 Cooling u uuu D 1 5
11. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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 LINCOLN 5 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Machine fails to hold the output Rough or dirty commutator heat consistently Brushes may be worn down to Limit Field circuit may have variable resistance connection or inter mittent open circuit due to loose connection or broken wire Electrode lead or work lead connection may be poor Wrong grade of brushes may have been installed on gener ator Field rheostat may be making poor contact and overheating Welder starts but fails to generate Generator or exciter brushes current may be loose or missing Exciter may not be operating If all recommended possible areas Field circuit of generator orlof misadjustment have been exciter may be open checked and
12. ed joints or to the metal framework of a building which has been effectively grounded The U S National Code lists a number of alternate means of grounding electrical equipment LIFT BAIL A lift bail is provided for lifting with a hoist A WARNING Lift only with equipment of adequate lifting capacity 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 FALLING Do not lift machine if lift bale is EQUIPMENT can damaged cause injury Do not operate machine while suspended from lift bale PIPELINER 2000 KUBOTA LINCOLN 5 A 4 TRAILER See Optional Features If the user adapts a non Lincoln trailer the user must assume responsibility that the method of attachment and usage does not result in a safety hazard nor dam age the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be
13. 300 DC amps with output ratings as follows RATED OUTPUT DUTY CYCLE 200A 28V 200A 40V The unit is also capable of providing 1 75 kw of 120V DC auxiliary power This unit uses the Kubota V2403M Industrial water cooled diesel engine DESIGN FEATURES CONTROL PANEL Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine The welder controls consist of a five step Current Range Selector switch and a Fine Current Adjustment rheostat The welder is equipped with a Start button Glow Plug button Ignition switch Idler control switch hour meter Engine Protection indicator light Remote Local Switch and Receptacle The control panel also contains a three prong ground ing type receptacle for auxiliary power an engine tem perature gauge a battery charging ammeter an oil pressure gauge and a high idle RPM adjustment knob WELDING GENERATOR The Pipeliner amp 2000 KUBOTA uses the old style round all copper FJW Generator frame which pro vides the customer with the original Classic pipe welding arc ENGINE IDLER The Pipeliner amp 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
14. 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona res piraci n la cabeza fuera de 105 humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria OR ames 1c OF OR S LPK HE SR ER TR S e 42274 ESAE Belle 247 MASP Ash 75 4274714 712 Assis Qual oe fyn dal sut e co gal bic ja d Aach Jiul J oi Mall ge oaa SI Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m q
15. and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information SAFETY i PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tensi
16. each morning before start ing to weld 3 Put a drop of oil on the Current Range Selector shaft at least once every month 4 When necessary remove the sediment bowl if so equipped from beneath the fuel tank and clean out any accumulated dirt and water 5 Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in the engine manufacturer s manual COOLING SYSTEM The PIPELINER 2000 KUBOTA is equipped with a pressure radiator Keep the radiator cap tight to pre vent loss of coolant Clean and flush the cooling sys tem periodically to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type BEARINGS This welder is equipped with a double shielded ball bearing having sufficient grease to last indefinitely under normal service Where the welder is used con stantly or in excessively dirty locations it may be nec essary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease COMMUTATOR AND BRUSHES A WARNING Uncovered rotating equipment can be dangerous Use ca
17. if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes
18. suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER e TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 8 Relier la terre le chassis
19. the problem persists Exciter may have lost excita Contact your local Lincoln tion Authorized Field Service Facility Series field and armature cir cuit may be open circuited Welding arc is loud and spatters Current setting may be too excessively high Polarity may be wrong Welding current too great or too Exciter output low causing low small compared to indication on output compared to dial indica the dial tion Operating speed too low or too high Arc continuously pops out 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
20. your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 1 0 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source LINCOLN 8 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire weldin
21. 5 A 3 INSTALLATION A 3 PRE OPERATION INSTALLATION WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists e 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 3 ENGINE EXHAUST can kill 4 open well ventilated areas 0 exhaust outside PARTS Do not with doors open guards off lt Stop engine before servicing Keep away from moving parts 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 CAUTION Use of an incorrect arrester may lead to engine dam age or performance loss Contact the engine manu facturer for specific recommendations LO
22. CATION VENTILATION Always operate the welder with the doors closed Leaving the doors open changes the designed air flow and may cause overheating The welder should be located to provide an unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an outside area A CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150mm beyond the equipment on all side MACHINE GROUNDING According to the United States National Electrical Code the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle Some state local or other codes or unusual operating circumstances may require the machine frame to be grounded It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly A machine grounding stud marked with the symbol is provided on the welding generator frame foot In gen eral if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat
23. HL HV3N M3H9S GNNOYD 3NION3 WEM HLIM A9 8 00 00 RE n O HALV 3N FN9 309 QNOOH9 QNnOH9 wa o 9 9 i We eex 0 Vibe x os HOSN3S HOSN3S SNE 93345 EEN 931935 3NISN3 NOLLO3HIQ SIHL NI 3NION3 1 p 39nv9 1 k SuOl1SIs3u HO1VNd TV HLIM SV NAOHS HSS Hd 9018 QV31 ai 9 IM H3I3NAV 1V201 NI SNENL 002 HOLIMS k NMOHS OHINO0 SLOWSY HO 19071 HOH HOLIMS 80121146 0019 d QN3S HOLMS val 8 98 28 Sad 10 Y lt 1v1S0 HH 1 6 ML 815 209 02 d N S dia s 2 HOLIMS Zb Sn YVAN MAYOS Ee GG 1 Le Dee WOU 2212 ves HOLIMS 0215 ene x 5358 Am nis as zem TT in 8 vita 9 HNYd 1OHINO9 A SSNHVH 18015 T Q vague SNIHIM OL C3IL 3HIA 809 Saa 1NnHS 2NONI WoLvnLov 2 19 TANVd ddM IA SV NAOHS DIAGRAMS SSdNdVH OLNI GAIL HIM ANY NddO 133181 V0Z 0731 ALON 59019 MO
24. LDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated ELECTRIC AND SR MAGNETIC FIELDS 359 may be dangerous 2 a Electric current
25. NO9 31OW3H HO 1Y2019803 HOLIMS HO10313S HONG z IHOLIMS w HO1VNd ITV DIAGRAMS 8024 Saud 110 SE velo 10 ics lt VO09 veel ivisoamu Eu ef gis eh e 0 voz 5 HAONIS dial 5 HV N HOLIMS ce vg o o 4 NOILIN9I 242 010 veg z d ra NO HOLIMS ANAL Gd Aerm L 380 lt 20 93885 Lib 15 825 IOV1d 9 d ylb8 6o 9 THNYd IOHLNOO Soe CNIH38 SS3NHVH 1915 Wlan OH NES ONIBIM OL G3IL 3HIA S S ANNHS 99 3NION3 pole _ 95 309 HOLVNLOV ec s SET hos e 309 5 Ze 99 Ru 10HLNO9 WO Q MA vv 6 88 SV NMOHS SAHSNHE 5 el S n MOTIBA A SS3NHVH OLNI GALL Ts po E e 4 3HIM NadO 7 ME V8 nv 148151 VOL 091 LON ole Ge Sond MOTD OL WHLNAN 5 91 AVH9 iste er 6 CJH HO XOV TE WIA 335 1OHINO 3NI9N3 OL G31O3NNOO SAVI Y 3009 40109 Avs UWE OH SV NMOHS SIN NOdWOO T3NVd 1OHINOO TVI HO193NNO9 LINN TOHILNOO ANIONS 86tL 3803 803 WNVH9VIQ ONIHIM 0006 H3NI T3dld
26. O 7 IOLNOO 3 pt SHOLSISSY TVWNOILdO 1OH LNOO 31084 S v26M NMOHS SV NOILO3HIO S491v9 ANIONS MAHIIA 9 8 09 99 JAILISOd 3ALLVO3N 1IOdHH INI Ce 9 1 38 LSNW 50731 353 1 YVAN AHOS 278 g ONO 3NISN3 01 QNOd5 QNTOH9 dii T wos 86x 09 Va M ES HOSN S HOSN3S o 531935 32018 Qv31HO1VH3N39 NOLLISOd 1 201 1 HOLIMS SNHNL 1 v 3onvo 3unss3td NMOHS 10H1NOO 31ON3H HO V907 404 HOLIMS HO109413S 0019 99 98 28 5 48885 JAIL 1 3NION3 9 10 D M H3I3AWV SNunLZ 02 693 Di H3QN3S IHOLIMS S Hd 110 vis dOIVNd ITV vos Vel D FH 202 1 1503 209 ru Zb 3S d YVAN 5 Wy Praw 80 5 20 1OVld 9 H od RO TOHINOOWdd ie n 531935 e 09 p 5 H3GN3S HOLINS mW e 4 MOIE K BE IMS dL AV TH LUV d KA 6 10 o 0 19 x8 VIr8 NI HOW 4009 MOTA 3LIHWM 3718 N3349 9
27. 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 LINCOLN 8 1 TROUBLESHOOTING E 1 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 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3
28. PIPELINER 2000 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 EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be carelul OPERATOR S MANUAL ISO 9001 4 mom i as T i d Under LINCOLN Copyright Lincoln Global Inc e 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 216 486 1751 WEB SITE www lincolnelectric com to ISO 9001 Requirements CERTIFICATE NUMBER 30273 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS t Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHI
29. TA 3LIHWM NMOHS N J Nd d5 9 HO VI 11 130 33S LINN TOH1NOO 3NION3 OL GALOSNNOO SQV3T1X 3009 40109 av31 UNO WOtd SV NMOHS SLNANOdWOO T3NYd TOHLNOO 117130 HOLO3NNOO LINN 1OdINO9 3NI9N3 L6SLL 3803 803 IWVH9VIG H3NI T3dld F 2 PIPELINER 200D KUBOTA LINCOLN LL DIAGRAMS F 3 Jequunu epoo 1u uudinb SAID e 104 1USUJJBdS 2011S 94 0 lqIB li SI eu Ji sjeued eJnsojoue Jo euo uo SDISUI pejsed si epoo e oul siy SSUIUOBUU 40 eq jou Aew 1 AlUO O SI 5141 310 0LGZZM SNOILO3NNOO 3S3H L 9NDIVIN N3HM ONINNNY 38 LON LSNW 3NIHOVIA AIGNASSY IVISOWH HL 052 HOCH HSN OAN 0119 NNO9 QV31AAV3H 2 609 24 INON 990 0 0334 341M Sd 90 NO HOLO3NNOO OL WM NO LOANNOO 1814 HOLO3NNOO WOH 1014 DT 3AOW3H 3NIHOVIN NO JINON Q334 SHIM AN3HHNO IWYS NI HOSN3S LNSYYND 1949 TVNIWH 1 LAdLNO NO 3NLVO3N SIVNINHAL 114100 SOd 0f O3N 9 504 OL LOANNOO d 1 WOIN 10d IOH1NOO SLOWSY OO 91 1 WOILN 10d ASVO OL LOANNO
30. UT Duty DC CURRENT RANGE VOLTS RATED AMPS CYCLE Fine Adjustments in each Range 200 Amp DC Welder LINCOLN PLUS RATING 40V 200A All Copper Windings NEMA RATING 28V 200A 40 300 Amps Pure DC Power Generator ogv DC Max OCV 1600RPM RATED OUTPUT 104 F 40 C GENERATOR 1 75 kW 15 Amps 120V DC 9 35 Duty Cycle PHYSICAL DIMENSIONS HEIGHT DEPTH WEIGHT 45 500 in 68 00 in 1302 Ibs 1156 mm 1727 mm 592 kg 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 LINCOLN A 2 INSTALLATION A 2 GENERAL DESCRIPTION The Pipeliner 200D is a heavy duty engine driven DC arc welding power source capable of providing DC constant current output for stick welding and DC TIG welding With the addition of the optional Wire Feed Module the Pipeliner 200D will provide constant volt age output for running the LN 25 wire feeder The optional Remote Control Kit provides a remote control rheostat for remote fine current and open cir cuit voltage adjustment The Pipeliner 200D KUBOTA has Diesel Engine Protection In the event of sudden low oil pressure or high coolant temperature the engine immediately shuts down The Pipeliner 200D KUBOTA has a current range of 40
31. are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PIPELINER 2000 KUBOTA LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual Engine does not start Lack of fuel Air mixed in the fuel system Clogged fuel filter Irregular and faulty fuel supply Injector pump trouble Glow plug not heated Clogged air cleaner No compression Engine protection light is ON Engine does not turn over A Faulty Ignition switch and Injector pump solenoid Insufficient charging or com plete discharge of the battery If all recommended possible areas Improper viscosity of the of misadjustment have been cating oil checked and the problem persists Contact your local Lincoln Irregular running of the engine A Air mixed in the fuel system Authorized Field Service Facility Uneven fuel injection Faulty fuel injector pump Clogged fuel filter Defective governor Engine itself defective Engine stops during operation and 1 Lack of fuel in the fuel tank the Engine Protection light does not turn on Clogged fuel filter Air mixed in the fuel system Faulty function of the engine Engine stops during operation andj See Light Code Diagnoses the Engine Protection light does Attached turn on CAUTION If for any reason you d
32. battery or using a jumper bat tery to start the engine be sure the battery polarity is connected properly The correct polarity is negative ground Damage to the engine alternator and the Engine Control Unit can result from incorrect con nection 1 Proper operation of the idler requires good grounding of the Engine Control Unit current sensing printed circuit board and battery 2 If desired the welder can be used without automat ic idling by setting the Idler switch to the High position NAMEPLATES Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replace ment item number PURGING AIR FROM FUEL SYSTEM KUBOTA V2403M ENGINE A WARNING Keep fuel clear of open 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 If the engine is running rough and you suspect air has been trapped in the fuel system e g the engine was allowed to run out of fuel perform the following steps using qualified personnel 1 Fully open the air bleeding valve by turning it counter clockwise it is located on top of the fuel injection pump next to the oil filler see figure D 1 FIGURE D 1 2 Turn the engine by pressing the start button until the engine runs smoothly this should take appro
33. cedure 5 Observe the oil pressure If no pressure shows within 30 seconds stop the engine and consult the engine operating manual To stop the engine turn the IGNI TION switch to OFF 6 If the engine protection warning light comes on during cranking or after start up the IGNITION switch must be turned OFF to reset the engine protection system 7 Allow the engine to run at high idle speed for several minutes to warm the engine Stop the engine and recheck the oil level after allowing sufficient time for the oil to drain into the pan If the level is down fill it to the full mark again The engine controls were properly Set at the factory and should require no adjusting when received COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 5 F 20 C it maybe desirable to install cold starting aides Note Extreme cold weather staring may require longer glow plug operation A 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 Contact a Kubota Service Representative for any engine adjustments that may be required STOPPING THE ENGINE 1 Turn the IGNITION switch to OFF At the end of each day s welding c
34. chine In some cases it may be neces sary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is com plete Always use the greatest care when work ing near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop 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 e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 40 cm 4 MOVING PARTS can injure Do not operate with doors open or A guards off X Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual GENERAL INSTRUCTIONS 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation 2 Current Range Selector contacts should not be greased To keep the contacts clean rotate the cur rent control through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice
35. cts 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 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 Also see item 1 b SAFETY ME WELDING and CUTTING gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures
36. du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to 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
37. e Current Adjustment setting to get 175 amps Some arc instability may be experienced with EXX10 electrodes when trying to operate with long arc tech niques at settings at the lower end of the open circuit voltage range A CAUTION DO NOT attempt to set the Current Range Selector between the five points designated on the nameplate These switches have a spring loaded cam which almost eliminates the possibility of setting this switch between the designated points PIPELINER 200D KUBOTA LINCOLN 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 lt gt lt 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 contro
38. e tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PIPELINER 2000 KUBOTA LINCOLN 8 7 TROUBLESHOOTING E 7 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 Check for loose or disconnected 1 Load too small Try load wire running between weld 1 Check Idler circuit wiring The direction of above 100 Watts selector switch and output stud 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 Contact Kubota Sensing PCB 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 LINCOLN 8 Jequunu epoo 1u uudinb y e 104 1USUJJBdS eu O 1NA s ou j sjeued y Jo euo uo ou LL pisui paysed s epoo 1ejnonued
39. eeled 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 amp a light pack age K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit K965 1 Cable Rack K1858 1 AIR CLEANER SERVICE INDICATOR STICK OPTIONS K704 ACCESSORY SET Includes 35 ft 10 m of electrode cable and 30 ft 9 m of work cable head shield work clamp and electrode holder Cable is rated at 500 amps 60 duty cycle Remote Control Kit K924 5 Contains remote control rheostat and 100 ft 30 5 m cable for adjusting the OCV at the welding site For Codes 10910 and above Remote Control Kit K2464 1 Contains a remote control rheostat for adjusting the CC STICK OCV remote control potentiometer for adjusting the CV WIRE OCV and 100ft 30 5m cable WIRE FEED OPTIONS Wire Feed Module K623 1 Provides constant voltage CV output with improved arc stability for Innershield welding Excellent for MIG welding Recommended wire feeders are the LN 7 LN 23P and LN 25 Factory installed on the K1643 6 LN 15 Wire Feeder K1870 1 2 Portable CC CV unit for flux cored and MIG welding LN 23P Wire Feeder K316L 1 Portable CV unit for Innershield pipe welding Control cable operates con tactor inside Wire Feed Module for cold electrode Require
40. flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on
41. function of the engine Overloading Clogged air cleaner Faulty Charging Loose fan belt Faulty wiring If all recommended possible areas of misadjustment have been Faulty battery checked and the problem persists Contact your local Lincoln Worn out alternator brush Authorized Field Service Facility Starter Motor does not run Loose or damaged wiring Drained voltage from battery Damaged starter motor including solenoid Engine Protection Light not com Broken Light Bulb ing on Faulty light wiring 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 LINCOLN E 6 TROUBLESHOOTING E 6 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 Replace Idler Idler Control switch Control Switch Y Y 12 VDC 0 VDC Contact Kubota Replace current Engine Repair Sensing PCB Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform th
42. g the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 spa
43. he 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 A 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 TABLE OF CONTENTS Page DECEM Section A Technical Specifications Susa co IR ON NEUES REC cL A 1 General Description ss A 2 D Sign Features A 2
44. heck the crankcase oil level drain accumulated dirt and water from the water separator and refill the fuel tank to minimize moisture condensation in the tank Also running out of fuel tends to draw dirt into the fuel system When hauling the welder between job sites close the valve on the water separator If the fuel supply is cut off or runs out while the fuel pump is operating air may be entrapped in the fuel distribution system If this happens bleeding of the fuel system may be necessary Use qualified person nel to do this per the instructions in the MAINTE NANCE section of this manual ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil consumption during initial operation excessive oil use wetstacking oil or tar like sub stance at the exhaust port or excessive smoke is not normal PIPELINER 200D KUBOTA LINCOLN B 2 OPERATION B 2 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 t
45. is system is NEGATIVE GROUND PIPELINER 200D KUBOTA LINCOLN 8 B 1 OPERATION B 1 ENGINE OPERATION A 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 0 ELECTRIC SHOCK can kill Do not touch electrically live parts electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS injure Do not operate with doors open or guards off lt Siop engine before servicing Keep away from moving parts o QA x See additional warning information at the front of this operator s manual Operate the welder with the doors closed Leaving the doors open changes the designed air flow and can cause overheating STARTING THE PIPELINER 200D KUBOTA V2403M DIESEL ENGINE 1 Turn the IDLER switch to HIGH 2 Turn the IGNITION switch to ON 3 Press the Glow Plug button for 20 to 30 seconds maximum 60 seconds 4 Press the Glow Plug button and the Start button at the same time When the engine starts running release both buttons If the engine fails to start in 20 seconds wait 30 seconds and repeat the above pro
46. l 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 39 gal hr 1 46 Itrs hr No Load High idle 1600 53 gal hr 2 00 Itrs hr No load 200 Amps 28 Volts 90 gal hr 3 42 Itrs hr Auxiliary Power 1 750 Watts 54 gal hr 2 04 Itrs hr PIPELINER 2000 KUBOTA LINCOLN P B 3 C1 ACCESSORIES C1 OPTIONAL FEATURES Field Installed GENERAL OPTIONS A 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 TRAILER K953 1 Two wh
47. 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 Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com 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 t
48. o 200ft 61m 200 to 250ft 61 to 76m PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instruc tions supplied with this machine WARNING e Stop engine while fueling e Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling e Wipe up spilled fuel and allow DIESEL FUEL fumes to clear before starting can engine cause fire Do not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada OIL m This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W 30 oil This oil should be acceptable for most typical ambient temperatures Consult the engine operation manual for specific engine manufacturer s recommendations Upon receipt of the welder check the engine dipstick to be sure the oil is at the full mark DO NOT overfill FUEL gi Fill the fuel tank with the grade of fuel recommended in the Engine Operator s manual Make sure the valve on the water separator is in the open position COOLING SYSTEM The radiator has been filled at the factory with a 50 50 mixture of ethylene glycol antifreeze and water Check the radiator level and add a 50 50 solution as needed see engine manual or antifreeze container for alternate antifreeze recommendations PIPELINER 2000 KUBOTA LINCOLN 8
49. o extensive light loading occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resistive load bank Note that any attempt to short the output studs by connecting the welding leads together direct shorting of the output studs or connecting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty 2 Set the welder controls for an output current and voltage within the welder rating and duty cycle Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level WELDER OPERATION A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp GASES be dangerous Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away ARC RAYS can burn Wear eye ear and body protection K x DUTY CYCLE The NEMA output rating of the PIPELINER 200D KUBOTA is 200 amperes at 28 arc volts on a 60 duty cycle consul
50. o 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 LINCOLN E 4 TROUBLESHOOTING E 4 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 ACTUATOR IS STUCK REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED LONG 1 SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND 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 B B FOR 1 SECOND LEAD TO L TERMINAL ON ALTERNATOR MAYBE SHORTED TO GROUND CHECK FAULTY ALTERNATOR CHECK LONG 1 SHORT 4 HIGH WATER TEMPERATURE DETECTED AMOUNT OR QUALITY OF COOLANT INCORRECT FOR 1 SECOND CHECK FAULTY WATER TEMPERATURE SWITCH CHECK THAT WK STUD IS OPEN WHEN ENGINE IS NOT RUNNING LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDE HECK LONG 1 SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 SHORT 1 0 RPM IS DETECTED AND 12V IS DETECTED FAULTY RPM SENSOR CHECK FOR GOOD CONNECTION FROM L TERMINAL ON ALTERNATOR FAULTY ECU CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
51. on des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation
52. operat ed environmental conditions likely maintenance 5 Conformance with federal state and local laws 1 1 Consult your federal state and local laws regarding specific requirements for use on public highways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for nents such as suspension axles and tires Mount equipment base to metal bed frame of vehicle e Follow vehicle manufacture s instructions POLARITY CONTROL AND CABLE SIZES With the engine off route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail See size recommendations below For positive polarity connect the electrode cable to the terminal marked For Negative polarity con the electrode cable to the stud These con nections should be checked periodically and tightened if necessary When welding at a considerable distance from the welder be sure you use ample sized welding cables INSTALLATION 4 Cables Sizes for Combined Length of Electrode Plus Work Cable Duty Cycle Up t
53. re 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 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 PIPELINER 2000 KUBOTA LINCOLN 8 D 2 MAINTENANCE D 2 Replace brushes when they wear within 1 4 3 5mm of the pigtail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experi enced maintenance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes After stoning blow out the dust with low pressure air Arcing or excessive exciter brush wear indicates a possible misaligned shaft Have an authorized Field Service Shop check and realign the shaft IDLER MAINTENANCE CAUTION Before doing electrical work disconnect the bat tery When installing a new
54. s LN 23P Adapter Kit K350 1 and Gun and Cable Assembly LN 23P Adapter Kit K350 1 Required to adapt LN 23P to any Lincoln power source Makes 14 pin con nection at power source Magnum 250 Innershield Gun for LN 23P K355 10 For lighter weight and easier handling Rated 250 amps 60 duty cycle For 068 through 5 64 1 7 through 2 0 mm Innershield wire and includes reduced speed switch For pipewelding an M11476 62 gun tube is recommended LN 25 Wire Feeder K449 Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid amp Internal Contactor Requires Wire Feed Module Remote Voltage Control Kit for LN 25 K444 2 Provides 25 ft 7 5m of remote output voltage control and output jumper 2 and 4 for machines having 14 pin MS type connector Magnum 350 Innershield Gun for LN 25 K126 2 For self shielded wire with 15 ft 4 5m cable For 062 3 32 1 6 2 8mm wire Magnum 200 MIG Gun for LN 25 K497 3 With 15 ft 4 5m cable For 025 0 6m wire Magnum Gun Connector KiT ood 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 2000 KUBOTA LINCOLN 8 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS AA WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the ma
55. switch on the panel locks the idler in the full speed position when desired AUXILIARY POWER 1 75 kw of nominal 120V DC Output voltage is main tained within 1096 at all loads up to rated capacity WELDER ENCLOSURE The complete welder is rubber mounted on a rugged steel C channel base The output terminals are placed at the side of the machine so that they are protected by the door The output terminals are labeled and CRANKING SYSTEM A 12V electric starter is standard AIR CLEANER Heavy duty two stage dry type MUFFLER A muffler and stainless steel exhaust outlet pipe are standard ENGINE HOUR METER A meter to record the hours of operation ENGINE PROTECTION The system shuts the engine down in the event of sudden low oil pressure or high coolant temperature A warning light on the control panel will indicate such a fault To reset the engine for restarting turn the ignition switch off then on Refer to Troubleshooting section for all warning light fault codes CUSTOM ARC HIGH IDLE RPM ADJUSTMENT A Potentiometer is mounted on the Control Panel that allows the operator to adjust the high idle engine speed between 1450 and 1600 RPM S This is to allow further adjustment of the OCV Total OCV adjustment range is about 15 volts OIL DRAIN VALVE A ball valve hose and clamp are standard REMOTE CONTROL The Remote Local switch and Receptacle are standard PIPELINER 2000 KUBOTA LINCOLN
56. t 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 The Current Range Selector provides five overlap ping current ranges The Fine Current Adjustment adjusts the current from minimum to maximum within each range Open circuit voltage is also controlled by the Fine Current Adjustment permitting control of the arc characteristics A high open circuit voltage setting provides the soft buttering arc with best resistance to pop outs pre ferred for most welding To get this characteristic set the Current Range Selector to the lowest setting that still provides the current you need and set the Fine Current Adjustment near maximum For example to obtain 175 amps and a soft arc set the Current Range Selector to the 190 120 position and then adjust the Fine Current Adjustment for 175 amps When a forceful digging arc is required usually for vertical and overhead welding use a higher Current Range Selector setting and lower open circuit volt age For example to obtain 175 amps and a forceful arc set the Current Range Selector to the 240 160 position and the Fin
57. tter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 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 u
58. uina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico toque as partes el tricas nuas e e e 5 gt 49 AH ab AN db juil alil e Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgehause oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e e BE RTI BB BOSUB ezido sel HAE Abeyi cis Jal la Jai ye Aale WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR
59. 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Also see item 1 c 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 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode
60. xi mately 10 seconds 3 Fully close the air bleeding valve by turning it clockwise Contact your Kubota Engine repair facility if problems persist PIPELINER 200D KUBOTA LINCOLN 8 D 3 MAINTENANCE D 3 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 NOTE2 ose MAINTENANCE ITEM TYPE OR QUANTITY ITT ER Concentration of 5O60 Water Ethylene TI TR coon NOTES 9 59s 9 0L IL EngneoilselNOTE1 R IRL engine NOTE 7 amp 6 0qts 76L ncudngfeg R R oitte e Drain water separator amp fus strainer T T R Fuel ner cariste TT Tension of altemator belt TT T AWemaordebetwesr TT L R AWemaordiwebet Ruben 17450 37010 c Air filter earlier check may be req d Ar tereemet Donatdson P821575 clearances 0071 0086 Exhaust 0071 0086 I Eeeealsystems LEAF nuts and bolts oriighiness I eats or engine damage IT TIT T SS Inspect C Clean R Replace Notes 1 Consult Engine

Lincoln Electric 11498 Welder User Manual

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