Lincoln Electric PIPELINER 11498 Operator'S Manual Download Page 7

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TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

General Description ...............................................................................................A-2

Design Features ....................................................................................................A-2

Pre-Operation Installation ......................................................................................A-3

Safety Precautions ..........................................................................................A-3

Exhaust Spark Arrester ...................................................................................A-3

Location/Ventilation .........................................................................................A-3

Machine Grounding .........................................................................................A-3

Lift Bail ............................................................................................................A-3

Trailers ............................................................................................................A-4

Polarity Control and Cable Sizes ....................................................................A-4

Pre-Operation Service ...........................................................................................A-4

Oil ....................................................................................................................A-4

Fuel .................................................................................................................A-4

Cooling System ...............................................................................................A-4

Battery Charging .............................................................................................A-5

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Operation .........................................................................................................Section B

Engine Operation...................................................................................................B-1

Starting The Kubota V2403M Engine, Cold Weather Starting .......................B-1

High Altitude Operation ...................................................................................B-1

Stopping the engine ........................................................................................B-1

Break-In...........................................................................................................B-1

Welder Operation...................................................................................................B-2

Duty Cycle .......................................................................................................B-2

Control of Welding Current..............................................................................B-2

Idler Operation ................................................................................................B-3

Auxiliary Power ...............................................................................................B-3

Fuel Consumption Data ..................................................................................B-3

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Accessories .....................................................................................................Section C

Optional Features (Field Installed) ........................................................................C-1

Wire Feed Options.................................................................................................C-1

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Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

General Instructions ..............................................................................................D-1

Cooling System .....................................................................................................D-1

Bearings ................................................................................................................D-1

Commutator and Brushes .....................................................................................D-1

Idler Maintenance..................................................................................................D-2

Nameplates ...........................................................................................................D-2

Purging Air from Fuel System................................................................................D-2

Engine Service Chart ............................................................................................D-3

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Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1

Welder Troubleshooting ........................................................................................E-2

Engine Troubleshooting Guide ................................................................E-3,E-4,E-5

Electronic Idler Troubleshooting Guide...........................................................E-6,E-7

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Diagrams ..........................................................................................................Section F

Wiring Diagram ...................................................................................F-1,F-2,F-3,F-4

Dimension Print......................................................................................................F-5

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Parts List .....................................................................................................P-504 Series

Summary of Contents for PIPELINER 11498

Page 1: ...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 careful 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 Wor...

Page 2: ...AKER 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 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 ava...

Page 3: ...or cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...s to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Page 5: ...riés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Elo...

Page 6: ...ecially 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 ...

Page 7: ...l Consumption Data B 3 ________________________________________________________________________ Accessories Section C Optional Features Field Installed C 1 Wire Feed Options C 1 ________________________________________________________________________ Maintenance Section D Safety Precautions D 1 General Instructions D 1 Cooling System D 1 Bearings D 1 Commutator and Brushes D 1 Idler Maintenance D ...

Page 8: ... DIESEL ENGINE RATED OUTPUT 104 F 40 C WELDER HEIGHT WIDTH DEPTH WEIGHT 45 50 2 in 24 00 in 68 00 in 1302 lbs 1156 mm 610 mm 1727 mm 592 kg RATED OUTPUT 104 F 40 C GENERATOR DESCRIPTION RATED DC OUTPUT 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 60 40 300 Amps Pure DC Power Gener...

Page 9: ...Generator frame which pro vides the customer with the original Classic pipe welding arc ENGINE IDLER The Pipeliner 200D KUBOTA is equipped with an electronic automatic engine idler It automatically increases and decreases engine speed when starting and stopping welding or using auxiliary power A built in time delay permits changing electrodes before the engine slows to its low idle speed The Idler...

Page 10: ...nded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat ed joints or to the metal framework of a building which has been effectively grounded The U S National Code lists a number of alternate means of grounding electrical equipment LIFT BAIL A lift bail is provided for lifting wi...

Page 11: ...i e travel speed rough ness of surface on which the trailer will be operat ed environmental conditions likely maintenance 5 Conformance with federal state and local laws 1 1 Consult your federal state and local laws regarding specific requirements for use on public highways POLARITY CONTROL AND CABLE SIZES With the engine off route the electrode and work cables through the strain relief bracket on...

Page 12: ...orking 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 b...

Page 13: ...T can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual WARNING COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even do...

Page 14: ...uit voltage range 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 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES GAS...

Page 15: ...nnot be adjusted c If the welding or power load is not re started before the end of the time delay the engine control unit reduces the engine to low idle speed AUXILIARY POWER 1 75 kVA of 120 V DC auxiliary power is availiable at the receptacle located on the control panel When the High Speed Adjustment knob is in the MIN position the voltage of the DC auxiliary output may be reduced to below the ...

Page 16: ...m wire Magnum Gun Connector KiT K466 1 Connects Magnum 200 MIG gun to LN 25 Wire Feeder 62 gun tube for Pipe Welding KP1909 1 Recommended modification for K355 X or K345 X guns with 90 gun tubes Compatible with K126 1 2 K264 8 and K355 10 C 1 ACCESSORIES C 1 PIPELINER 200D KUBOTA OPTIONAL FEATURES Field Installed GENERAL OPTIONS Pipe Thawing with an arc welder can cause fire explosion damage to el...

Page 17: ...e clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease COMMUTATOR AND BRUSHES Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be thrown out by the rotat ing armature when stoning the commutator Shifting of the commutato...

Page 18: ...cuit 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 KUB...

Page 19: ...NTHS EVERY 400 HOURS OR 12 MONTHS EVERY 500 HOURS OR 15 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE NOTE 2 TYPE OR QUANTITY I l o c y l G e n e l y h t E r e t a W 0 5 0 5 I L 0 9 s t r q 5 9 R I r e t l i f g n i d u l c n i L 6 7 s t r q 0 8 R R R R C R I I 0 1 0 7 9 0 8 4 7 1 a t o b u K R C 5 7 5 1 2 8 P n o s d l a n o D R 6 8 0 0 1 7 0 0 t s u a h x E 6 8 0 0 1 7 0 0 e k a t n I I I I...

Page 20: ...OSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of 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 Au...

Page 21: ...of generator or exciter may be open 4 Exciter may have lost excita tion 5 Series field and armature cir cuit may be open circuited 1 Current setting may be too high 2 Polarity may be wrong 1 Exciter output low causing low output compared to dial indica tion 2 Operating speed too low or too high 1 Current Range Selector switch may be set at an inter mediate position If all recommended possible area...

Page 22: ... on 1 Lack of fuel 2 Air mixed in the fuel system 3 Clogged fuel filter 4 Irregular and faulty fuel supply Injector pump trouble 5 Glow plug not heated 6 Clogged air cleaner 7 No compression 8 Engine protection light is ON 1 Faulty Ignition switch and or Injector pump solenoid 2 Insufficient charging or com plete discharge of the battery 3 Improper viscosity of the lubri cating oil 1 Air mixed in ...

Page 23: ...HEN ENGINE IS NOT RUNNING LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED CHECK LONG 1 SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 SHORT 1 0 RPM IS DETECTED AND 12V IS DETECTED 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 LONG 2 SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT FAULTY ACTUATOR CHECK FOR...

Page 24: ...g Starter Motor does not run Engine Protection Light not com ing on 1 Excess engine oil 2 Too low viscosity of the engine oil 3 Faulty injection timing 1 Unsuitable fuel 2 Excess injection 3 Faulty function of the engine 4 Overloading 5 Clogged air cleaner 1 Loose fan belt 2 Faulty wiring 3 Faulty battery 4 Worn out alternator brush 1 Loose or damaged wiring 2 Drained voltage from battery 3 Damage...

Page 25: ... the Auto Position Check for Continuity through Idler Control Switch Open Closed Check Voltage across Replace Idler Idler Control switch Control Switch 12 VDC 0 VDC Contact Kubota Replace current Engine Repair Sensing PCB Facility 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 Facilit...

Page 26: ... Engine Repair Facility 1 Check Idler circuit wiring The direction of leads entering the current sensor may be incorrect E 7 TROUBLESHOOTING PIPELINER 200D KUBOTA E 7 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE 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 t...

Page 27: ...ly It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 28: ...ly It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 29: ...ly It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 30: ...Y X B G W F G ORANGE WHITE JUMPER WHITE JUMPER PIN CABLE CONNECTION TABLE C D E LEAD COLOR RED BLUE CCW BLUE RED ORANGE K2464 1 REMOTE CONTROL WIRING CONNECTION DIAGRAM CONNECT TO CASE RESISTORS REMOTE CONTROL BOX CV WIRE CONTROL POT CC STICK CONTROL ...

Page 31: ...4 13 75 349 25 4 00 101 6 4 00 101 6 23 00 584 2 8 25 209 55 41 66 1058 16 3 25 82 55 57 70 1465 58 O 56 SKID O 56 SKID N B N A NOTES Ø 20 62 523 75 18 50 469 9 40 94 1039 88 45 50 1155 7 N A CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE BUT ON FUEL N B 56 14 2 TRAILER MOUNTING HOLES MONTING HOLE MONTING HOLE ...

Page 32: ...NOTES PIPELINER 200D KUBOTA ...

Page 33: ...NOTES PIPELINER 200D KUBOTA ...

Page 34: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 35: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 36: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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