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PIPELINER ® 200D KUBOTA

PIPELINER 200D

OPERATOR’S MANUAL

For Machines with Code Number 11498, 11591, 11644

IM965-BMarch, 2010

Safety Depends on YouLincoln arc welding equipmentis designed and built with safetyin mind. However, your overallsafety can be increased byproper instal lat ion ... andthoughtful operation on yourpart. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUTREADING THIS MANUAL ANDTHE SAFETY PRECAUTIONSCONTAINED THROUGHOUT.And, most importantly, thinkbefore 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

• World's Leader in Welding and Cutting Products •

Copyright © Lincoln Global Inc.

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN 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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your rightside, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL andACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Jan ‘09

iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:•Away from areas where they may be struck or subjected tophysical damage.

•A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Jan ‘09

Refer to http://www.lincolnelectric.com/safety for additional safety information.

ivSAFETYiv

Mar ‘93

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dansles positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde 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 desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

vv

TThhaannkk YYoouu for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave 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.

CUSTOMER ASSISTANCE POLICYThe 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 LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty 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 controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying 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.comfor any updated information.

vi vi TABLE OF CONTENTS

Page

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1General Description ...............................................................................................A-2Design Features ....................................................................................................A-2Pre-Operation Installation ......................................................................................A-3

Safety Precautions ..........................................................................................A-3Exhaust Spark Arrester ...................................................................................A-3Location/Ventilation.........................................................................................A-3Machine Grounding.........................................................................................A-3Lift Bail ............................................................................................................A-3Trailers ............................................................................................................A-4Polarity Control and Cable Sizes ....................................................................A-4

Pre-Operation Service ...........................................................................................A-4Oil ....................................................................................................................A-4Fuel .................................................................................................................A-4Cooling System ...............................................................................................A-4Battery Charging .............................................................................................A-5

________________________________________________________________________Operation .........................................................................................................Section B

Engine Operation...................................................................................................B-1Starting The Kubota V2403M Engine, Cold Weather Starting .......................B-1High Altitude Operation ...................................................................................B-1Stopping the engine ........................................................................................B-1Break-In...........................................................................................................B-1

Welder Operation...................................................................................................B-2Duty Cycle.......................................................................................................B-2Control of Welding Current..............................................................................B-2Idler Operation ................................................................................................B-3Auxiliary Power ...............................................................................................B-3Fuel Consumption Data ..................................................................................B-3

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Features (Field Installed) ........................................................................C-1Wire Feed Options.................................................................................................C-1

________________________________________________________________________Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1General Instructions ..............................................................................................D-1Cooling System .....................................................................................................D-1Bearings ................................................................................................................D-1Commutator and Brushes .....................................................................................D-1Idler Maintenance..................................................................................................D-2Nameplates ...........................................................................................................D-2Purging Air from Fuel System................................................................................D-2Engine Service Chart ............................................................................................D-3

________________________________________________________________________Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1Welder Troubleshooting ........................................................................................E-2Engine Troubleshooting Guide ................................................................E-3,E-4,E-5Electronic Idler Troubleshooting Guide...........................................................E-6,E-7

________________________________________________________________________Diagrams ..........................................................................................................Section F

Wiring Diagram...................................................................................F-1,F-2,F-3,F-4Dimension Print......................................................................................................F-5

________________________________________________________________________Parts List .....................................................................................................P-504 Series

INSTALLATION

PIPELINER® 200D KUBOTA

A-1A-1

TECHNICAL SPECIFICATIONS - PIPELINER® 200D KUBOTA

Make/Model Description Speed (RPM) Displacement Starting CapacitiesSystem

4 Cylinder4 Cycle 148.53 cu. in 12VDC battery Fuel: 15 gal.

Naturally Aspirated (2.43 ltrs) (Group 45, 650 57 LKubota 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 9.5 LCompliant Block/Crankcase 3.43” x 4.03” w/ built in reg. Coolant 9.5 Qts.

27.8HP @1600 RPM 9.0 L

INPUT - 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 RANGEVOLTS @ RATED AMPS CYCLE Fine Adjustments in each Range

200 Amp DC Welder LINCOLN PLUS RATING 40V @ 200AAll Copper Windings NEMA RATING 28V @ 200A 60% 40-300 Amps

Pure DC Power Generator

Auxiliary Power (1)

1.75 kW 15 Amps @ 120V DC @ 35% Duty Cycle

PHYSICAL DIMENSIONS

(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).

98V DC Max. OCV @ 1600RPM

A-2INSTALLATION


A-2

GENERAL DESCRIPTION

The Pipeliner® 200D is a heavy duty engine drivenDC arc welding power source capable of providing DCconstant current output for stick welding and DC TIGwelding. With the addition of the optional Wire FeedModule the Pipeliner® 200D will provide constant volt-age output for running the LN-25 wire feeder.

The optional Remote Control Kit provides a remotecontrol rheostat for remote fine current and open cir-cuit voltage adjustment.

The Pipeliner® 200D KUBOTA has Diesel EngineProtection. In the event of sudden low oil pressure orhigh coolant temperature, the engine immediatelyshuts down.

The Pipeliner® 200D KUBOTA has a current range of40-300 DC amps with output ratings as follows:

The unit is also capable of providing 1.75 kw of 120VDC auxiliary power.

This unit uses the Kubota V2403M Industrial watercooled diesel engine.

DESIGN FEATURESCONTROL PANELBoth the engine and the welder controls are locatedon one recessed panel at the exciter end of themachine. The welder controls consist of a five step“Current Range Selector” switch and a “Fine CurrentAdjustment” rheostat. The welder is equipped with a“Start” button,”Glow Plug” button, “Ignition” switch,“Idler” control switch, hour meter, “Engine Protection”indicator l ight, “Remote / Local Switch andReceptacle.

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 oilpressure gauge and a high idle RPM adjustmentknob.

WELDING GENERATORThe Pipeliner® 200D KUBOTA uses the old style,round, all copper FJW Generator frame which pro-vides the customer with the original “Classic” pipewelding arc.

ENGINE IDLERThe Pipeliner® 200D KUBOTA is equipped with anelectronic automatic engine idler. It automaticallyincreases and decreases engine speed when startingand stopping welding or using auxiliary power. A built-in time delay permits changing electrodes before theengine slows to its low idle speed. The “Idler” controlswitch on the panel locks the idler in the full speedposition when desired.

AUXILIARY POWER1.75 kw of nominal 120V DC. Output voltage is main-tained within ± 10% at all loads up to rated capacity.

WELDER ENCLOSUREThe complete welder is rubber mounted on a ruggedsteel “C” channel base.

The output terminals are placed at the side of themachine so that they are protected by the door. Theoutput terminals are labeled (+) and (-).

CRANKING SYSTEMA 12V electric starter is standard.

AIR CLEANERHeavy duty two-stage dry type

MUFFLERA muffler and stainless steel exhaust outlet pipe arestandard.

ENGINE HOUR METERA meter to record the hours of operation.

ENGINE PROTECTION - The system shuts theengine down in the event of sudden low oil pressureor high coolant temperature. A warning light on thecontrol panel will indicate such a fault. To reset theengine for restarting, turn the ignition switch off thenon. Refer to Troubleshooting section for all warninglight fault codes.

CUSTOM ARC™ HIGH IDLE RPM (OCV)ADJUSTMENT - A Potentiometer is mounted on theControl Panel that allows the operator to adjust thehigh idle engine speed between 1450 and 1600RPM’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 arestandard.

REMOTE CONTROL- The Remote/Local switch andReceptacle are standard.

200A @ 28V200A @ 40V

60%60%

RATED OUTPUT DUTY CYCLE

A-3INSTALLATION


A-3

PRE-OPERATION INSTALLATION

EXHAUST SPARK ARRESTERSome federal, state or local laws may require thatengines be equipped with exhaust spark arresterswhen they are operated in certain locations whereunarrested sparks may present a fire hazard. Thestandard muffler included with this welder does notqualify as a spark arrester. When required by localregulations, a suitable spark arrester must be installedand properly maintained.

Use of an incorrect arrester may lead to engine dam-age or performance loss. Contact the engine manu-facturer for specific recommendations.------------------------------------------------------------------------LOCATION/VENTILATION

Always operate the welder with the doors closed.Leaving the doors open changes the designed air flowand may cause overheating.

The welder should be located to provide an unrestrict-ed flow of clean, cool air. Also, locate the welder sothat engine exhaust fumes are properly vented to anoutside area.

MACHINE GROUNDING

According to the United States National ElectricalCode, the frame of this portable generator is notrequired to be grounded and is permitted to serve asthe grounding means for cord connected equipmentplugged into its receptacle.

Some state, local, or other codes or unusual operatingcircumstances may require the machine frame to begrounded. It is recommended that you determine theextent to which such requirements may apply to yourparticular situation and follow them explicitly. Amachine grounding stud marked with the symbol isprovided on the welding generator frame foot. In gen-eral, if the machine is to be grounded, it should beconnected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going intothe ground for at least ten feet and having no insulat-ed joints, or to the metal framework of a buildingwhich has been effectively grounded. The U.S.National Code lists a number of alternate means ofgrounding electrical equipment.

LIFT BAILA lift bail is provided for lifting with a hoist.

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC SHOCK can kill.• Do not touch electrically live parts orelectrode with skin or wet clothing.• Insulate yourself from work andground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas orvent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open orguards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------See additional warning information at thefront of this operator’s manual.------------------------------------------------------------------------

WARNING

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SUR-FACES.Where there is a combustible surface directly understationary or fixed electrical equipment, the surfaceshall be covered with a steel plate at least.06”(1.6mm) thick, which shall extend not more than5.90”(150mm) beyond the equipment on all side.------------------------------------------------------------------------

CAUTION

• Lift only with equipment ofadequate lifting capacity.

• Be sure machine is stablewhen lifting.

• Do not lift this machine usinglift bale if it is equipped with aheavy 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.------------------------------------------------------------------------

WARNING

PRE-OPERATION SERVICE

READ the engine operating and maintenance instruc-tions supplied with this machine.-

OIL

This unit is supplied from the factory with the enginecrankcase filled with a high quality SAE 10W/30 oil.This oil should be acceptable for most typical ambienttemperatures. Consult the engine operation manualfor specific engine manufacturer’s recommendations.Upon receipt of the welder, check the engine dipstickto be sure the oil is at the “full” mark. DO NOT overfill.

FUEL

Fill the fuel tank with the grade of fuel recommendedin the Engine Operator’s manual. Make sure the valveon the water separator is in the open position.

COOLING SYSTEM

The radiator has been filled at the factory with a 50-50mixture of ethylene glycol antifreeze and water.Check the radiator level and add a 50-50 solution asneeded (see engine manual or antifreeze container foralternate antifreeze recommendations).

CAUTION

A-4INSTALLATION


A-4

TRAILER (See Optional Features)

If the user adapts a non-Lincoln trailer, the user mustassume responsibility that the method of attachmentand usage does not result in a safety hazard nor dam-age the welding equipment. Some of the factors to beconsidered 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 unduestress to the framework.

3. Proper placement of the equipment on the trailer toensure stability side to side and front to back whenbeing moved and when standing by itself whilebeing operated or serviced.

4. Typical conditions of use, i.e., travel speed, rough-ness of surface on which the trailer will be operat-ed; environmental conditions, likely maintenance.

5. Conformance with federal, state and local laws. (1)(1) Consult your federal, state and local laws regarding specificrequirements for use on public highways.

POLARITY CONTROL AND CABLE SIZES

With the engine off, route the electrode and workcables through the strain relief bracket on the baseand connect to the studs located below the fuel tankmounting rail. (See size recommendations below.)For positive polarity, connect the electrode cable tothe terminal marked “+”. For Negative polarity, con-nect the electrode cable to the “-” stud. These con-nections should be checked periodically and tightenedif necessary.

When welding at a considerable distance from thewelder, be sure you use ample sized welding cables.

RECOMMENDED COPPER CABLE SIZESCables Sizes for Combined Lengthof Electrode Plus Work Cable

Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.(61 to 76m)

200 60% 1 1/0

VEHICLE MOUNTING

Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.

• Only transport this Equipment on serviceablevehicles which are rated and designed for suchloads.

• Distribute, balance and secure loads so vehicleis stable under conditions of use.

• Do not exceed maximum rated loads for compo-nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame ofvehicle.

• Follow vehicle manufacture’s instructions.------------------------------------------------------------------------

WARNING

• Stop engine while fueling.• Do not smoke when fueling.• Keep sparks and flame awayfrom tank.

• Do not leave unattended whilefueling.

• Wipe up spilled fuel and allowfumes to clear before startingengine.

• Do not overfill tank, fuel expan-sion may cause overflow.

DIESEL FUEL ONLY-Low sulphur fuel or ultra lowsulphur fuel in U.S.A. and Canada.------------------------------------------------------------------------

WARNING

DIESEL FUELcan

cause fire

A-5INSTALLATION


A-5

Battery Charging

The PIPELINER® 200D KUBOTA is equipped with awet charged battery. The charging current is automat-ically regulated when the battery is low (after startingthe engine) to a trickle current when the battery is fullycharged.

When replacing, jumping or otherwise connecting thebattery to the battery cables, the proper polarity mustbe observed. This system is NEGATIVE GROUND.

GASES FROM BATTERY can explode.• Keep sparks, flame and cigarettes

away.

BATTERY ACID can burn eyes andskin.• Wear gloves and eye protection and

be careful when boosting, chargingor 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 andbattery clamp. When reinstalling, connect thenegative cable last.

c) Using a booster - connect the positive lead tothe battery first, then connect the negativelead to the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:a) Installing a new battery.

b) Using a booster.

Use correct polarity - Negative Ground.

• To prevent BATTERY DISCHARGE, if you havean ignition switch, turn it off when engine is notrunning.

• To prevent BATTERY BUCKLING, tighten nutson battery clamp until snug.

------------------------------------------------------------------------

WARNING

B-1OPERATIONB-1

ENGINE OPERATION

Operate the welder with the doors closed. Leaving thedoors open changes the designed air flow and cancause overheating.

STARTING THE PIPELINER® 200D KUBOTA V2403MDIESEL 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, releaseboth buttons. If the engine fails to start in 20 seconds,wait 30 seconds and repeat the above procedure.

5. Observe the oil pressure. If no pressure shows within30 seconds, stop the engine and consult the engineoperating manual. To stop the engine, turn the “IGNI-TION” switch to “OFF”.

6. If the engine protection warning light comes on duringcranking or after start up, the “IGNITION” switch mustbe turned “OFF” to reset the engine protection system.

7. Allow the engine to run at high idle speed for severalminutes to warm the engine. Stop the engine andrecheck the oil level, after allowing sufficient time forthe oil to drain into the pan. If the level is down, fill it tothe full mark again. The engine controls were properlyset at the factory and should require no adjusting whenreceived.


Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.

-------------------------------------------------------ELECTRIC SHOCK can kill.• Do not touch electrically live parts orelectrode with skin or wet clothing.• Insulate yourself from work andground• Always wear dry insulating gloves.-------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas orvent exhaust outside.

--------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open orguards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------See additional warning information at thefront 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 down toabout -5°F (-20°C), it maybe desirable to install cold-starting aides.

Note: Extreme cold weather staring may requirelonger glow plug operation.

Under NO conditions should ether or otherstarting fluids be used!------------------------------------------------------------------------HIGH ALTITUDE OPERATION:

At higher altitudes, output derating may be necessary.For maximum rating, derate the welder 4% for every300 meters (984 ft.) above 1500 meters (4920 ft.).

Contact a Kubota Service Representative for anyengine adjustments that may be required.

STOPPING THE ENGINE

1. Turn the “IGNITION” switch to “OFF”

At the end of each day’s welding, check the crankcaseoil level, drain accumulated dirt and water from thewater separator and refill the fuel tank to minimizemoisture condensation in the tank. Also, running outof fuel tends to draw dirt into the fuel system.

When hauling the welder between job sites, close thevalve on the water separator.

If the fuel supply is cut off or runs out while the fuelpump is operating, air may be entrapped in the fueldistribution system. If this happens, bleeding of thefuel 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 weoffer. While it is normal to see a small amount ofcrankcase oil consumption during initial operation,excessive oil use, wetstacking (oil or tar like sub-stance at the exhaust port), or excessive smoke is notnormal.

WARNING

B-2OPERATIONB-2


WELDER OPERATION

------------------------------------------------------------------------

DUTY CYCLE

The NEMA output rating of the PIPELINER® 200DKUBOTA is 200 amperes at 28 arc volts on a 60%duty cycle (consult Specifications in this manual foralternate ratings). Duty cycle is based on a ten minuteperiod; thus, the welder can be loaded at rated outputfor six minutes out of every ten minute period.

CONTROL OF WELDING CURRENT

DO NOT TURN THE “CURRENT RANGE SELEC-TOR” WHILE WELDING because the current mayarc 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 withineach range. Open circuit voltage is also controlled bythe “Fine Current Adjustment” permitting control of thearc 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, setthe “Current Range Selector” to the lowest setting thatstill provides the current you need and set the “FineCurrent Adjustment” near maximum. For example: toobtain 175 amps and a soft arc, set the “CurrentRange Selector” to the 190-120 position and thenadjust the “Fine Current Adjustment” for 175 amps.

When a forceful “digging” arc is required, usually forvertical and overhead welding, use a higher “CurrentRange Selector” setting and lower open circuit volt-age. For example: to obtain 175 amps and a forcefularc, set the “Current Range Selector” to the 240-160position and the “Fine Current Adjustment” setting toget 175 amps.

Some arc instability may be experienced with EXX10electrodes when trying to operate with long arc tech-niques at settings at the lower end of the open circuitvoltage 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 whichalmost eliminates the possibility of setting this switchbetween 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 & GASES can be dangerous.• Keep your head out of the fumes.• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire orexplosion.• Keep flammable material away.

ARC RAYS can burn.• Wear eye, ear, and body protection.

WARNING

CAUTION

CAUTION

Larger machines with a capacity of 350 amperes andhigher, which are operated at low or no-load condi-tions for extended periods of time are especially sus-ceptible to the conditions described above. Toaccomplish 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 forsome period of time during the engine’s early life.However, if the welder is subjected to extensive lightloading, occasional moderate to heavy loading of theengine may sometimes be necessary. Caution mustbe observed in correctly loading a diesel/generatorunit.

1. Connect the welder output studs to a suitableresistive load bank. Note that any attempt toshort the output studs by connecting the weldingleads together, direct shorting of the output studs,or connecting the output leads to a length of steelwill result in catastrophic damage to the generatorand voids the warranty.

2. Set the welder controls for an output current andvoltage within the welder rating and duty cycle.Note that any attempt to exceed the welder ratingor duty cycle for any period of time will result incatastrophic damage to the generator and voidsthe warranty.

3. Periodically shut off the engine and check thecrankcase oil level.

B-3OPERATIONB-3


IDLER OPERATION

Start the engine with the “Idler” switch in the “High”position. Allow it to run at high idle speed for severalminutes to warm the engine. See Specifications foroperating speeds.

The idler is controlled by the “Idler” toggle switch onthe welder control panel. The switch has two posi-tions as follows:

1. In the “High” position, the engine control unitincreases the engine to high idle speed.

2. In the “Auto” / position, the idler oper-ates as follows:

a. When welding or drawing power for lights or tools(approximately 100 watts minimum) from the recep-tacles, the engine operates at high idle speed.

b. When welding ceases or the power load is turnedoff, 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 beforethe end of the time delay, the engine control unitreduces the engine to low idle speed.

AUXILIARY POWER

1.75 kVA of 120 V DC auxiliary power is availiable atthe receptacle located on the control panel.

When the High Speed Adjustment knob is in the MINposition, the voltage of the DC auxiliary output may bereduced to below the rating on the nameplate of themachine. It is recommended that the High Idle SpeedAdjustment knob should be in the MAX position whenusing the DC auxiliary output.

Always replace blown fuse with type rated for DC volt-age (i.e. Cooper Bussmann Inc. Model LP-CC-15 orLittlefuse Model CCMR-15.

PIPELINER® 200D WITH KUBOTA V2403M DIESEL ENGINETYPICAL FUEL CONSUMPTION DATA

Low idle (1400 RPM ) .39 gal/hr (1.46 ltrs/hr )No Load

High idle ( 1600 Rpm ) .53 gal/hr (2.00 ltrs/hr )No load

200 Amps @ 28 Volts .90 gal/hr (3.42 ltrs/hr )

Auxiliary Power1,750 Watts .54 gal/hr (2.04 ltrs/hr)

WIRE FEED OPTIONS

Wire Feed Module (K623-1) - Provides constantvoltage (CV) output with improved arc stability forInnershield welding. Excellent for MIG welding.Recommended wire feeders are the LN-7, LN-23Pand LN-25. (Factory installed on the K1643-6).

LN-15 Wire Feeder (K1870-1,-2)-Portable CC/CV unitfor flux-cored and MIG welding.

LN-23P Wire Feeder (K316L-1)-Portable CV unit forInnershield pipe welding. Control cable operates con-tactor inside Wire Feed Module for “cold” electrode.Requires LN-23P Adapter Kit (K350-1) and Gun andCable 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 250amps, 60% duty cycle. For .068 through 5/64” (1.7through 2.0 mm) Innershield wire and includesreduced speed switch. For pipewelding, an M1147662° gun tube is recommended.

LN-25 Wire Feeder (K449)-Portable CC/CV unit forflux-cored and MIG welding. Includes Gas Solenoid &Internal Contactor. Requires Wire Feed Module.

Remote Voltage Control Kit for LN-25 (K444-2)Provides 25 ft. (7.5m) of remote output voltage controland output jumper (2 and 4) for machines having 14pin 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)-With15 ft. (4.5m) cable. For .025 (0.6m) wire.

Magnum Gun Connector KiT (K466-1) ConnectsMagnum 200 MIG gun to LN-25 Wire Feeder.

62° gun tube for Pipe Welding (KP1909-1)-Recommended modification for K355-X or K345-Xguns with 90° gun tubes. Compatible with K126-1,-2K264-8 and K355-10.

C-1ACCESSORIESC-1


OPTIONAL FEATURES (Field Installed)

GENERAL OPTIONS

Pipe Thawing with an arc welder can cause fire,explosion, damage to electric wiring or to the arcwelder if done improperly. The use of an arcwelder for pipe thawing is not approved by theCSA, nor is it recommended or supported byLincoln Electric.------------------------------------------------------------------------Spark Arrestor Kit (K903-1) - Includes a heavy gagesteel, approved spark arrestor, clamp and adapter formounting to the muffler exhaust pipe.

TRAILER (K953-1) - Two-wheeled trailer with optional fenderand light package. For highway use, consult applicable feder-al, state, and local laws regarding possible additional require-ments. There is a choice of 2 hitches, a fender & a light pack-age.

K953-1 TrailerK958-1 Ball HitchK958-2 Lunette Eye Hitch K959-1 Fender & Light KitK965-1 Cable Rack

K1858-1 AIR CLEANER SERVICE INDICATOR

STICK OPTIONS

K704 ACCESSORY SET - Includes 35 ft.(10 m) ofelectrode cable and 30 ft.(9 m) of work cable, head-shield, work clamp and electrode holder. Cable israted at 500 amps, 60% duty cycle.

Remote Control Kit (K924-5) - Contains remotecontrol rheostat and 100 ft.(30.5 m) cable for adjustingthe OCV at the welding site. (For Codes 10910 andabove.)

Remote Control Kit (K2464-1) - Contains a remotecontrol rheostat (for adjusting the CC “STICK” OCV),remote control potentiometer (for adjusting the CV“WIRE” OCV), and 100ft.(30.5m) cable.

WARNING

D-1MAINTENANCED-1

SAFETY PRECAUTIONS

GENERAL INSTRUCTIONS

1. Blow out the welder and controls with an air hose atleast once every two months. In particularly dirtylocations, this cleaning may be necessary once aweek. Use low pressure air to avoid driving dirt intothe insulation.

2. “Current Range Selector” contacts should not begreased. To keep the contacts clean, rotate the cur-rent control through its entire range frequently.Good practice is to turn the handle from maximumto minimum setting twice each morning before start-ing to weld.

3. Put a drop of oil on the “Current Range Selector”shaft at least once every month.

4. When necessary, remove the sediment bowl, if soequipped, from beneath the fuel tank and cleanout any accumulated dirt and water.

5. Follow the engine service schedule in this manualand the detailed maintenance and troubleshooting inthe engine manufacturer’s manual.

COOLING SYSTEM

The PIPELINER® 200D KUBOTA is equipped with apressure 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 andoverheating the engine. When antifreeze is needed,always use the permanent type.

BEARINGS

This welder is equipped with a double-shielded ballbearing having sufficient grease to last indefinitelyunder 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. Apad of grease one inch wide, one inch long, and oneinch high weighs approximately one half ounce. Over-greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of thearea. Wipe the fittings completely clean and use cleanequipment. More bearing failures are caused by dirtintroduced during greasing than from insufficientgrease.

COMMUTATOR AND BRUSHES

Uncovered rotating equipment can be dangerous.Use care so your hands, hair, clothing or tools donot catch in the rotating parts. Protect yourselffrom 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, andbrushes by removing the covers. DO NOT remove orreplace these covers while the machine is running.Commutators and slip rings require little attention.However, if they are black or appear uneven, havethem cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Neveruse emery cloth or paper for this purpose.


Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may be neces-sary to remove safety guards to performrequired maintenance. Remove guards onlywhen necessary and replace them when themaintenance 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 coolingblower fan. If a problem cannot be corrected byfollowing the instructions, take the machine tothe 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.

------------------------------------------------------------------------ENGINE EXHAUST 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 atfront of this operator’s manual.

-----------------------------------------------------------

WARNING

WARNING

D-2MAINTENANCED-2

Replace brushes when they wear within 1/4”(3.5mm)of the pigtail. A complete set of replacement brushesshould be kept on hand. Lincoln brushes have acurved face to fit the commutator. Have an experi-enced maintenance man seat these brushes by lightlystoning the commutator as the armature rotates at fullspeed until contact is made across the full face of thebrushes. After stoning, blow out the dust with lowpressure air.

Arcing or excessive exciter brush wear indicates apossible misaligned shaft. Have an authorized FieldService Shop check and realign the shaft.

IDLER MAINTENANCE

Before doing electrical work, disconnect the bat-tery.------------------------------------------------------------------------When installing a new battery or using a jumper bat-tery to start the engine, be sure the battery polarity isconnected properly. The correct polarity is negativeground. Damage to the engine alternator and theEngine Control Unit can result from incorrect con-nection.

1. Proper operation of the idler requires goodgrounding of the Engine Control Unit, currentsensing 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 thismachine - or at least yearly - inspect all nameplatesand labels for legibility. Replace those which are nolonger clear. Refer to the parts list for the replace-ment item number.

PURGING AIR FROM FUEL SYSTEM(KUBOTA V2403M ENGINE)

Keep fuel clear of open flames or arcs, allowengine to cool before working on the fuel system.Wipe up any spilled fuel and do not start engineuntil fumes clear.------------------------------------------------------------------------If the engine is running rough and you suspect air hasbeen trapped in the fuel system, (e.g. the engine wasallowed to run out of fuel) perform the following stepsusing qualified personnel:

1. Fully open the air bleeding valve by turning itcounter clockwise, it is located on top of the fuelinjection pump next to the oil filler. (see figure D.1)

FIGURE D.1

2. Turn the engine by pressing the start button untilthe engine runs smoothly (this should take approxi-mately 10 seconds).

3. Fully close the air bleeding valve by turning itclockwise.

Contact your Kubota Engine repair facility if problemspersist.


CAUTION

WARNING

Air Bleeding Valve

D-3D-3


MAINTENANCE

If necessary use shorter periods.These preventive maintenance periods apply to average conditions of operation.Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.

(3) Fill slowly! Ensure correct quantity is used.(2) Consult Engine Operators Manual for additional maintenance schedule information.(1) Consult Engine Operators Manual for oil recommendations.

Notes:

ENGINE SERVICE

S25833

R = ReplaceC = CleanI = Inspect

EVERY DAY OR EVERY 8 HOURSFIRST SERVICE (50 HOURS)

EVERY 100 HOURS OR 3 MONTHSEVERY 150 HOURS OR 4 MONTHS

EVERY 30O HOURS OR 9 MONTHSEVERY 400 HOURS OR 12 MONTHS

EVERY 500 HOURS OR 15 MONTHSEVERY 600 HOURS OR 18 MONTHS

ENGINE SERVICE (NOTE 2)TYPE OR QUANTITY

IlocylG enelyhtE/retaW 05/05I

L0.9 ,.strq 5.9RI

)retlif gnidulcni( L6.7 ,.strq 0.8RRR R

CR

II

01079-08471 # atobuKRC

575128P # nosdlanoDR"6800.-"1700. tsuahxE ,"6800.-"1700. ekatnII

II

II

MAINTENANCE ITEM

Coolant (NOTE 3)

Fuel filter canister

Coolant levelConcentration of antifreeze

Tension of alternator drive belt

Engine oil level (NOTE 1)Engine oil (NOTE 1 & 3)Engine oil filterDrain water separator & fuel strainer

Alternator drive belt wearAlternator drive beltAir filter (earlier check may be req'd)Air filter element

Leaks or engine damageBattery

Valve clearancesElectrical systemsAll nuts and bolts for tightness

E-1TROUBLESHOOTING


E-1

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate 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 symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

E-2TROUBLESHOOTINGE-2


Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

Machine fails to hold the output(heat) consistently.

Welder starts but fails to generatecurrent.

Welding arc is loud and spattersexcessively.

Welding current too great or toosmall compared to indication onthe dial.

Arc continuously pops out.

1. Rough or dirty commutator.

2. Brushes may be worn down toLimit.

3. Field circuit may have variableresistance connection or inter-mittent open circuit due toloose connection or brokenwire.

4. Electrode lead or work leadconnection may be poor.

5. Wrong grade of brushes mayhave been installed on gener-ator.

6. Field rheostat may be makingpoor contact and overheating.

1. Generator or exciter brushesmay be loose or missing.

2. Exciter may not be operating.

3. Field circuit of generator orexciter 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 toohigh.

2. Polarity may be wrong.

1. Exciter output low causing lowoutput compared to dial indica-tion.

2. Operating speed too low or toohigh.

1. “Current Range Selector”switch may be set at an inter-mediate position.

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

Flashing the exciter field consists of passing current through the fields using an external source of 6 to 125 volts of DC powerfrom a storage battery or DC generator. If using a DC generator, keep the generator turned off except when actually applyingthe 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 generatorvoltage should build up.





CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


Engine does not start.

Engine does not turn over.

Irregular running of the engine.

Engine stops during operation andthe Engine Protection light doesnot turn on.

Engine stops during operation andthe Engine Protection light doesturn 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 orInjector pump solenoid.

2. Insufficient charging or com-plete discharge of the battery.

3. Improper viscosity of the lubri-cating oil.


2. Uneven fuel injection (Faultyfuel injector pump).


4. Defective governor.

5. Engine itself defective.

1. Lack of fuel in the fuel tank.



4. Faulty function of the engine.

See Light Code DiagnosesAttached.






CAUTION

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 VERIFYPLUNGER PULLS IN WHEN ENERGIZED

LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND LOW OIL - CHECK OIL LEVEL ON DIPSTICKFAULTY OIL PRESSURE SWITCH - CHECK THAT "WK"STUD IS OPEN WHEN ENGINE IS RUNNINGLEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BEGROUNDED - CHECK

LONG 1, SHORT 3 "L" TERMINAL IS GROUNDED ON ALTERNATOR BROKEN OR LOOSE BELTFOR 1 SECOND LEAD TO "L" TERMINAL ON ALTERNATOR MAYBE

SHORTED TO GROUND- CHECKFAULTY ALTERNATOR - CHECK

LONG 1, SHORT 4 HIGH WATER TEMPERATURE DETECTED AMOUNT OR QUALITY OF COOLANT INCORRECTFOR 1 SECOND - CHECK

FAULTY WATER TEMPERATURE SWITCH - CHECK THAT"WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNINGLEAD 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 CONNECTIONFROM "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 PROPER COIL

RESISTANCE LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED- CHECK

LONG 2, SHORT 3 NOT ENABLED FOR LINCOLN PRODUCTS

LONG 2, SHORT 4 -50C WATER TEMPERATURE DETECTED FAULTY WATER TEMPERATURE SENSOR - CHECK FORPROPER RESISTANCELEAD 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 RESISTANCELEAD 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 - CHECK FOR CONTINUITY

BROKEN OR LOOSE BELT - INSPECTFAULTY ALTERNATOR - CHECK

LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR INCORRECT BATTERY - INSPECTFAULTY ALTERNATOR - CHECK

LONG 2, SHORT 8 LESS THAN 4 VOLTS TO RPM SENSOR AND/OR FAULTY ECU -CHECK FOR 12 VOLTS ON LEADS TO RPMACTUATOR SENSED BY ECU SENSOR AND ACTUATOR FROM ECU





CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE


White or Blue Smoke.

Dark Grey Smoke.

Faulty Charging.

Starter Motor does not run.

Engine Protection Light not com-ing on.

1. Excess engine oil.

2. Too low viscosity of theengine 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. Damaged starter motor(including solenoid).

1. Broken Light Bulb.

2. Faulty light wiring.

3. Faulty Engine Control Unit.


E-6TROUBLESHOOTING


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 Switchto the Auto Position

Check for Continuity through IdlerControl Switch

Open Closed

Check Voltage across Replace IdlerIdler Control switch Control Switch

12 VDC 0 VDC

Contact Kubota Replace currentEngine Repair Sensing PCBFacility


CAUTION

With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When:

The Arc is Struck Both Auxiliary Load

2. Check Idler circuit wiring. PossibleProblems are wires from Current SensingBoard reversed at idler switch or wiresconnected incorrectly at Current SensorMolex plug.

3. Check voltage across idler controlswitch.

12V 0V

Replace Current Contact Kubota Sensing PCB Engine Repair

Facility.

1. Check Idler circuit wiring. The direction ofleads entering the current sensor may beincorrect.

E-7TROUBLESHOOTING


E-7

ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE


CAUTION

Check for loose or disconnectedwire running between weld

selector switch and output stud.

1. Load too small. Try loadabove 100 Watts.

F-1DIAGRAMSF-1


NOTE: This diagram is for reference only. It may not be accurate for all m

achines 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, w

rite to the Service Departm

ent for a replacement. G

ive the equipment code number.

F-2DIAGRAMSF-2








F-3DIAGRAMSF-3








F-4DIAGRAMSF-4


S26097 A

Y X

BG W

FG

ORANGEWHITE JUMPERWHITE JUMPER

PINCABLE CONNECTION TABLE

CD

ELEAD COLORRED

BLUE

CCW

BLUE

REDORANGE

K2464-1 REMOTE CONTROL WIRING / CONNECTION DIAGRAM

CONNECT TO CASE

RESISTORS

REMOTE CONTROL BOX

CV “WIRE” CONTROL POT

CC “STICK” CONTROL

F-5DIMENSION PRINTF-5


S107

66-13 A

.01

24.00

609. 6

37.12

942.

85

68.00

1727

.2

26.00

660.

4

13.75

349.2

5

4.00

101.

64.0

010

1. 623

. 0058

4 .28.2

520

9.55

41.66

1058

.1 63.2

582

.5557

.7014

65.58

O.56

SKI

DO.

56 S

KID

N.B.

N.A..

NO T

ES: Ø

20.62

523.7

5

18.50

469. 9

40.94

1039

.8845

.5011

55. 7

N,A.

CEN

TER

OF G

RAVI

TY W

ITH

OIL A

ND W

ATER

IN E

NGIN

E, B

UT O

N FU

EL.

N.B.

56

/14.2

TRAI

LER

MOUN

TING

HOL

ES.

MONT

ING

HOLE

MONT

ING

HOLE

NOTES


WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

� Do not touch electrically live parts orelectrode with skin or wet clothing.

� Insulate yourself from work andground.

� No toque las partes o los electrodosbajo 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 contactavec des pièces sous tension.

� Isolez-vous du travail et de la terre.

� Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

� Isolieren Sie sich von denElektroden und dem Erdboden!

� Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

� Isole-se da peça e terra.

� Keep flammable materials away.

� Mantenga el material combustiblefuera del área de trabajo.

� Gardez à l’écart de tout matérielinflammable.

� Entfernen Sie brennbarres Material!

� Mantenha inflamáveis bem guarda-dos.

� Wear eye, ear and body protection.

� Protéjase los ojos, los oídos y elcuerpo.

� Protégez vos yeux, vos oreilles etvotre corps.

� Tragen Sie Augen-, Ohren- und Kör-perschutz!

� Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

� Keep your head out of fumes.� Use ventilation or exhaust to

remove fumes from breathing zone.

� Los humos fuera de la zona de res-piración.

� Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

� Gardez la tête à l’écart des fumées.� Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

� Vermeiden Sie das Einatmen vonSchweibrauch!

� Sorgen Sie für gute Be- undEntlüftung 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 máquinaantes de iniciar cualquier servicio.

� Débranchez le courant avant l’entre-tien.

� Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

� Não opere com as tampas removidas.� Desligue a corrente antes de fazer

serviço.� Não toque as partes elétricas nuas.

� Do not operate with panel open orguards off.

� No operar con panel abierto oguardas quitadas.

� N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

� Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

� Mantenha-se afastado das partesmoventes.

� Não opere com os paineis abertosou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

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