Wiring Diagram | Lincoln Electric 200 specs

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G-4

ELECTRICAL DIAGRAMS

G-4

WIRING DIAGRAM - CODE 10929 - (M20056)

PIPELINER 200D

WIRING DIAGRAM

LEAD COLOR CODE

ELECTRICAL SYMBOLS PER E1537

GLOW PLUGS

60A

B-BLACK OR

R-RED OR

CONTROL PANEL COMPONENTS

SHOWN AS VIEWED FROM REAR.

P10

GRAY

PINK

61

12 11 10 9 8

7 6

5 4 3 2 1

EXCITER BRUSHES SHOWN AS

G-GREEN

U-BLUE

J5

VIEWED FROM CONTROL PANEL

N-BROWN

W-WHITE

ENGINE

1 2 3 4 5 6 7 8 9 10

1

SHUNT

Y-YELLOW

N

FAILURE

LAMP

2

U

58

J1 IDLER / ENGINE J2 3

600B

PROTECTION

4

610

P.C. BOARD

-

+

602B

60C

R

53

53B

830

RECEPTACLE

720B

ENGINE

70

SERIES

HOUR

57

IDLER

G

GLOW

56A

IDLER

730A

41

41

START METER

SWITCH

GND-T

1

600

PLUG

56

SOLENOID

2

+ -

Y

IGNITION

PUMP SOLENOID GND-B

GROUND SCREW NEAR FUSE

42

3

X

58A

SWITCH

720A

RHEOSTAT

602A

4

42

W

54B

5

52

R

602

50B

51A

212A

54

58H

761

600A

6

W

50A

FUEL PUMP

820

J8

P9

G

W

F1

15A

67D

730B

60

54D

TEMPERATURE

SWITCH FOR LOCAL OR

SWITCH/ SENDER

610B

SELECTOR

REMOTE CONTROL SHOWN

STARTING

S

I

OIL PRESSURE

CURRENT 840

SWITCH

IN LOCAL POSITION

MOTOR

TEMPERATURE

SWITCH/SENDER

SENSOR

G

GAUGE

WK

GENERATOR LEAD BLOCK

G

844

4

SHOWN AS VIEWED WITH

GND-N

3

S

59

842

J3

ENGINE IN THIS DIRECTION

+

AMMETER

2

B

-

212B

841

1

SERIES

+

SHUNT

+

G

PRESSURE

+ EXC

42

31

+

50

S

I

ALTERNATOR

-

OIL

-

51

GAUGE

67C

5

INTERPOLE

A

51G

200

GND-M

NEGATIVE

POSITIVE

(CC-)

(CC+) & (CV+ WITH W.F.M.)

GROUND

GROUND

GROUND SCREW NEAR ENGINE GUAGES

N

TO BASE

TO

THESE LEADS MUST BE ROUTED THRU

U

ENGINE

CURRENT SENSOR IN SAME (CURRENT FLOW)

DIRECTION AS SHOWN.

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K924-5 REMOTE CONTROL (OPTIONAL)

Y X PLUG FOR

REMOTE CONTROL

POTENTIOMETER

G

CONNECT

TO CASE W

B

RESISTORS

REMOTE CONTROL

POTENTIOMETER BOX

WIRE FEED MODULE (OPTIONAL)

ON MACHINE, REMOVE PLUG "P10 FROM CONNECTOR "J5".

CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

INLINE
CONNECTORS	PLUG (P5)
W.F.M.	PLUG (P5)
W.F.M.
CONTROL
PANEL
CONNECT TO POS. & NEG.	#8 LEAD	WIRE FEED
CONNECT TO POS. & NEG.	POS.	WIRE FEED
OUTPUT TERMINALS	NEG.	MODULE
NEGATIVE CV		MODULE

OUTPUT TERMINAL	#2 HEAVY LEAD
PANEL	#2 HEAVY LEAD
	608
CONNECT TO NEG.	609
BRUSH HOLDER
	#2 HEAVY LEAD
	250 AMP THERMOSTAT ASSEMBLY

*MACHINE MUST NOT BE RUNNING WHEN MAKING THESE CONNECTIONS.

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B

M20056

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

PIPELINER® 200

Image 138

Lincoln Electric 200 service manual Wiring Diagram

Contents

Pipeliner Electric Magnetic Fields SafetyFor Engine Pipeliner Electric Shock can kill ARC Rays can burn Fumes and Gases For Electrically Iii LES Machines À Souder À Précautions DE SûretéPrécautions DE Sûreté Pour Transformateur ET À Master Table of Contents for ALL Sections Table of Contents Installation Section Height Width Depth Weight InstallationTechnical Specifications Pipeliner 200D Kubota K6090-11 Description Rated DC Output Design Features General Description Exhaust Spark Arrester PRE-OPERATION InstallationMachine Grounding Lift Bail OIL PRE-OPERATION ServiceTrailer Fuel Polarity Control and Cable Sizes Battery Charging Warning Table of Contents Operation Section Operation Engine OperationEngine BREAK-IN Control of Welding Current Welder OperationDuty Cycle Do not Turn the Current Range Selec Typical Fuel Consumption Data Idler Operation Table of Contents Accessories Section Wire Feed Module K623-1 Provides constant AccessoriesWire Feed Options LN-15 Wire Feeder K1870-1,-2-Portable CC/CV unit Table of Contents Maintenance Section Maintenance Safety Precautions Kubota V2203M Engine Idler MaintenancePurging AIR from Fuel System Nameplates Engine Service Figure D.2 Major Component Location Pipeliner 200D Kubota AA-1 Pipeliner 200D Perkins AIR Cleaner Engine Idler Muffler Engine Protection Lubrication Fuel System Governor Location / Ventilation Falling AA-4 PRE-OPERATION ServiceRead the engine operating and maintenance Vehicle Mountingwarning Battery Charging AA-5Ground Pipeliner 200D Perkins AA-6 BB-1 Rated Output Duty Cycle Cold Weather Starting Diesel EngineStarting the Pipeliner 200D Perkins Duty Cycle Control of Welding CurrentBB-4 Auxiliary Power Idler OperationBB-5 BB-6 CC-1 Optional Features Remote Control Kit K2464-1 Contains a remoteCC-2 DD-1 Engine Maintenance General Instructions Bearings Idler Maintenance Commutator and Brushes DD-4 Vent Screw Figure DD.2 Major Component Location DD-5 DD-6 AAA-1TABLE of Contents Installation Section AAA-1 AAA-2 Description Rated DC Output Duty Cycle DC Current Range AAA-3 Angle of Operation AAA-4 Gasoline Fuel Pipeliner 200G AAA-6 BBB-1 Safety Precautions Design Summary BBB-2Ignition System Starting the GM 3.0L Engine High Idle RPM OCV AdjustmentStopping the Engine BBB-3 Control of Welding Current Idler Operation TBI Deicing SystemBBB-4 CCC-1TABLE of Contents Accessories Section CCC-1 Accessories DDD-1TABLE of Contents Maintenance Section DDD-1 DDD-2 Guards off Stop engine before servicing Bearings Idle Control Maintenance DDD-3 Engine Service DDD-4 Figure DDD.1 Major Component Location DDD-5 Pipeliner 200G DDD-6 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation General Description Figure E.3 Engine Control Figure E.4 Engine Control Figure E.5 Engine Control ENGINE, Main Generator Armature Frame and DC Exciter DC Generator Machines Figure E.7 DC Generator Theory Pipeliner 1TABLE of Contents Troubleshooting & Repair F-1 Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Electric Shock Shunt Field Winding Test Troubleshooting & Repair Only Test. Perkins Receptacle. When the engine is Board Test. Replace if Oil Kubota EUC Codes Pipeliner 13TROUBLESHOOTING & REPAIRF-13 DC Exciter TestTest Description 14TROUBLESHOOTING & REPAIRF-14 Test Procedure 15TROUBLESHOOTING & REPAIRF-15 Figure F.2 Exciter Cover Removal 16TROUBLESHOOTING & REPAIRF-16 Shunt Coil and Series Coil Resistance Tests 17TROUBLESHOOTING & REPAIRF-17 Idler Solenoid TestMaterials Needed Test Procedure Quick Connect Leads 19TROUBLESHOOTING & REPAIRF-19 Main Generator Shunt Field Winding Test 20TROUBLESHOOTING & REPAIRF-20 Main Generator Shunt Field Winding Test 21TROUBLESHOOTING & REPAIRF-21 Figure F.6 Plug P10 PIN Assignments TAB Pipeliner 23TROUBLESHOOTING & REPAIRF-23 Flashing the Fields Procedure Figure F.7 Exciter Cover Removal Exiter Exciter To Negative To Positive Battery TerminalRaise Brush OFF Pipeliner 27TROUBLESHOOTING & REPAIRF-27 Engine Alternator Test 28TROUBLESHOOTING & REPAIRF-28 Test Procedure 29TROUBLESHOOTING & REPAIRF-29 OIL Pressure Temperature Switch Test 30TROUBLESHOOTING & REPAIRF-30 Procedure Return to Return to Section TOC Pipeliner 33TROUBLESHOOTING & REPAIRF-33 Current Sensor PCB Test 34TROUBLESHOOTING & REPAIRF-34 Figure F.11 Case Covers 35TROUBLESHOOTING & REPAIRF-35 Figure F.12 Current Sensing PCB Pipeliner Pipeliner 37TROUBLESHOOTING & REPAIRF-37 Engine Throttle Adjustment Test Perkins only 38TROUBLESHOOTING & REPAIRF-38 Figure F.13 Blower Paddle Mark Location 39TROUBLESHOOTING & REPAIRF-39 Engine Throttle Adjustment Test Perkins only 41TROUBLESHOOTING & REPAIRF-41 Scope Settings 42TROUBLESHOOTING & REPAIRF-42 Normal Open Circuit DC Weld Voltage Waveform 43TROUBLESHOOTING & REPAIRF-43 Machine Loaded Selector Switch AT MaximumTypical DC Weld Voltage Waveform Pipeliner 45TROUBLESHOOTING & REPAIRF-45 Description 46TROUBLESHOOTING & REPAIRF-46 Reassembly Field Coils Removal Procedure Reassembly DC Exciter Armature & Field Coils Pipeliner 49TROUBLESHOOTING & REPAIRF-49 Main Generator Frame Removal and Replacement Procedure 50TROUBLESHOOTING & REPAIRF-50 Figure F.16 Battery Panel Removal 51TROUBLESHOOTING & REPAIRF-51 Bolt / NUTDoor Hooks 52TROUBLESHOOTING & REPAIRF-52 Fuel Bowl Rails 53TROUBLESHOOTING & REPAIRF-53 Lead 54TROUBLESHOOTING & REPAIRF-54 Figure F.21 Choke Control Cable Removal Loosen Here 55TROUBLESHOOTING & REPAIRF-55 Shunt Leads DC Receptacle Quick Disconnect 56TROUBLESHOOTING & REPAIRF-56 57TROUBLESHOOTING & REPAIRF-57 58TROUBLESHOOTING & REPAIRF-58 FeetRemove Mounting NUTS, Washers Bolts Main Generator Frame Removal and Replacement Procedure Pipeliner 61TROUBLESHOOTING & REPAIRF-61 Main Generator Armature Removal and Replacement Procedure 62TROUBLESHOOTING & REPAIRF-62 Armature is now free to be removed from the engineSling Blower Paddle Mounting Bolts Lock Washers Welder DC Output RPM Pipeliner Table of Contents Diagram Section Wiring Diagram Electrical Diagrams Wiring Diagram Wiring Diagram Pipeliner 200D Wiring Diagram Wiring Diagram Code 11471 M21564 Schematic -COMPLETE Machine Code 10929 L12020 L12020 Optional L12362 Schematic Complete Machine Code 11471 L13350 L13350 S25973 Schematic IDLER/ENGINE Shutdown Code 10929 L10826