Lincoln Electric 200 service manual Optional, L12362

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G-8

ELECTRICAL DIAGRAMS

G-8

SCHEMATIC - COMPLETE MACHINE - CODE 11114, 11316 - (L12362)

L12362

ENGINEERING CONTROLLED

CHANGE DETAIL: Released A.02 from X

MANUFACTURER:

No

K924-5 REMOTE CONTROL

JUMPER PLUG IS BEHIND LOWER

LOWER RIGHTOFCONTROL PANEL

(OPTIONAL)

12 VOLT SUPPLY

RIGHTSIDE OFCONTROL PANEL

RPM CONTROL POTENTIOMETER

AMMETER SHOWS FULL

94

20

11

87

1

10,000 +/- 1,000 OHMS MAX

GLOW PLUG

DISCHARGE WHILE PRESSING

GLOW PLUG SWITCH

ENGINE

BUTTON

RATED VOLTAGE: 12V

ENGINE CONTROL UNIT (ECU)

2

86

2

TURN POT COUNTERCLOCKWISE TO

SPEED

93

17

REDUCE RESISTANCE AND SUBSEQUENTLY

RATED CURRENT: 22mA MAX

CCW

53

GLOW PLUGS

SENSOR

LOCATED BEHIND UPPER PORTION OFCONTROL PANEL

3

88

REDUCE RPM BY UP TO 150RPM

REMOTE CONTROL PLUG

3

BACK, RIGHT

60A

BACK, LEFTSIDE OFENGINE

51C

TYPICAL CURRENT

RATED VOLTAGE: 12V

G

SIDE OFENGINE

RATED CURRENT: 4.5A(MAX.)-TERMINAL #15

4

ALTERNATOR

DRAW IS 40 AMPS

LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16

40 AMP / 12 VOLT

26

64

L

69

13

Y

SENSOR OPERATION:

SENSES ALTERNATOR OUTPUT

IG

WATER

-4vF -> 18.80 kOHMS

B

X

TEMP.

FLASHES ALTERNATOR

104vF ->

1.14 kOHMS

212E

SENSOR

-40 TO 40 AMPS

212vF ->

.16 kOHMS

60

16

51B

W

25+/-1.25 OHMS EACH

BACK, LEFT

IGNITION

51

AMMETER

BACK, BOTTOM

SIDE OFENGINE

SWITCH

-

RATED VOLTAGE: 12V

1

9

15

212D

51A

50

STARTER

+

OFMACHINE

SHOWN IN "OFF"

+

RATED CURRENT: 2A

10

17

SOLENOID

BATTERY

COIL RESISTENCE:

57

34

18

POSITION

25

CCW

2.8 +/- .28 OHMS AT 20vC

12 VOLT

BACK, LEFTSIDE OFENGINE

212A

STARTER

12.6 VOLTS MIN

ENERGIZED FOR RUN

26

34

64+/-6.4 OHMS MAX

DE-ENERGIZED FOR STOP

ACTUATOR

SUPPLY

28

44

43

S

I

841B

50A

MOTOR

AT REST

14-14.5 VOLTS

ACTUATOR CONTROLS RPM

BACK, RIGHT

W

G

G

TEMPERATURE

WHILE RUNNING

MECHANICAL STOP WILL SHUT

SIDE OFENGINE

56

18

GAUGE

START

DOWN THE ENGINE AT 115%

OF RATED SPEED.

ECU CONNECTOR DETAIL

TEMPERATURE SWITCH / SENDER

LOWER LEFTOF

BUTTON

RHEOSTAT

ENGINE

SWITCH CLOSES

SENDER OPERATION:

212B CONTROL PANEL

RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY

COLOR: RED

PROTECTION

61

9

AT 230v+/-6vF

140vF -> 134+/-13.5 OHMS

62

OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED

REMOTE CONTROL BOX

12 VOLT

LIGHT

194vF -> 51.2+/-4.3 OHMS

SENDER IS APPROX.

WHEN THE IGNITION SWITCH IS "ON" AND THE ECU

THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE

NORMALLY OFF

CENTER OF

841A

212vF -> 38.5+/-3 OHMS

500 OHMS AT 70vF

SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT

PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT

212C

CONTROL PANEL

CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT

27

54

FRONT, LEFTSIDE OFENGINE

200

S

I

OIL PRESSURE

DOWN DUE TO A FAULT (EVEN IF THAT CONDITION

HOUR METER

+

58

6

DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE

WK

G

GAUGE

DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING

TURNED OFF THEN BACK ON TO RESTART THE ENGINE.

G

LOWER LEFTOF

52A

OUT OF FUEL), THE IGNITION SWITCH WILL NEED TO BE

CENTER OF

OIL PRESSURE SWITCH / SENDER

TURNED OFF THEN BACK ON TO RESTART THE ENGINE.

31

1

19

30

32

7

12

CONTROL PANEL

CONTROL PANEL

SWITCH CLOSES

SENDER OPERATION:

STARTER

841B

CONNECT TO

CONNECT TO

AT 6+/-2 PSI

0 PSI -> 10+/-5 OHMS

RELAY

60F

60E

GROUND FOR

70A

70B

GROUND FOR

40PSI -> 105+/-5 OHMS

WIRE-TIED TO HARNESS

80 PSI -> 187+/-5 OHMS

800RPM

1600RPM, LEAVE

844A

52B

BEHIND CONTROL PANEL

OPEN LEAD IS WIRE-TIED INSIDE THE 70C

UNCONNECTED

HARNESS BEHIND CONTROL PANEL

FOR 1800RPM

55

FLYBACK DIODE PREVENTS

VOLTAGE SPIKES IN SHUNT FIELD

FROM DAMAGING LOCAL/REMOTE

DC EXCITER

THE P10 PLUG IS ONLY ON UNITS WITHOUT

P10

TOGGLE SWITCH WHEN SWITCHED

GND-B

FDW-5M EXCITER COIL:

THE WIRE FEED MODULE. THE WIRE FEED

12 11 10 9 8

7 6 5

4

3 2 1

MODULE HAS A HARNESS THAT PLUGS

JUMPER PLUG IS

SHUNT FIELD

SHUNT COIL WINDINGS ARE 65+/-1.5 OHMS EACH

DC EXCITER USES RESIDUAL

DIRECTLY INTO J5.

SERIES COIL WINDINGS ARE .143 +/-.005 OHMS EACH

J5

WIRE-TIED UP BEHIND

MAGNETISM TO FLASH

-

+

LOCAL / REMOTE

IDLER SWITCH

SWITCH ON RIGHT

610

SIDE OFMACHINE (AS

SHOWN IN "AUTO

VIEWED FROM

IDLE" POSITION

SERIES FIELD

BRUSH POSITION SHOWN AS

RHEOSTAT

CONTROL PANEL)

VIEWED FROM CONTROL PANEL

CCW

64+/-6.4 OHMS MAX

610C

730A

DC AUXILIARY

602B

41

LOCATED BEHIND UPPER LEFT

610B

RECEPTACLE

602A

42

GND-T

J8

841

844

PORTION OFCONTROL PANEL

THESE LEADS MUST BE ROUTED THRU

5

4 6

3

1

2

SENSOR GROUNDS LEAD

ON SENSE OF WELD OR

CURRENT SENSING PC BOARD

CURRENT SENSOR IN SAME (CURRENT

P9

JUMPER PLUG IS

AUXILIARY LOAD

FLOW) DIRECTION AS SHOWN

G

SCHEMATIC S25973

LOWER LEFTOFCONTROL PANEL

602

WIRE-TIED UP BEHIND

J3-4

LOCAL / REMOTE

J3-1

DRIVER

610D

720C

720A

720B

X

Y SWITCH ON RIGHT

CIRCUITS

FUSE

SIDE OFMACHINE

J3-3

W

U

15 AMP

REMOTE

N

12 VOLT SUPPLY

842

J3-2

RECEPTACLE

GENERATOR LEAD BLOCK

LOCAL / REMOTE

SWITCH

SHOWN AS VIEWED WITH

3 TURNS

730B

67B

ENGINE IN THIS DIRECTION

SHOWN IN LOCAL

U

POSITION

N

LIGHT CODE

FAILURE DETECTED

POSSIBLE CAUSE - CORRECTIVE MEASURE

LONG 1, SHORT 1

RPM IS OVER 115% OF RATED RPM (2070 RPM)

ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED

SELECTOR SWITCH

SERIES FIELD

-

+

LOW OIL - CHECK OIL LEVEL ON DIPSTICK

90-MIN

SHUNT

LONG 1, SHORT 2

LOW OIL PRESSURE DETECTED FOR 1 SECOND

FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING

FJW-5AR COIL PAIR:

130-80

+

-

FIELD

LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK

22.5+/-.5 OHMS EACH

190-120

BROKEN OR LOOSE BELT - INSPECT

"L" TERMINAL IS GROUNDED ON ALTERNATOR

240-160

LONG 1, SHORT 3

LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK

INTERPOLE

LEAD COLOR CODE:

COMPONENT VALUE UNITS:

FOR 1 SECOND

220-MAX

LONG 1, SHORT 4

HIGH WATER TEMPERATURE DETECTED FOR 1

FAULTY ALTERNATOR - CHECK

COILS

G-GREEN

CAPACITOR: MFD/VOLTS

FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING

AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK

B-BLACK OR GRAY

SECOND

LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK

WELDING

O-ORANGE

RESISTOR: OHMS/WATTS

BRUSH POSITION SHOWN AS

LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS

FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION

R-RED OR PINK

CONNECTOR PIN NUMBERS:

LONG 2, SHORT 1

0 RPM IS DETECTED AND 12V IS DETECTED

VIEWED FROM CONTROL PANEL

GENERATOR

U-BLUE

FROM "L" TERMINAL ON ALTERNATOR

FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU

_

W-WHITE

EX. 12 PIN CONNECTOR

FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE

+

LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT

67A

Y-YELLOW

LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK

1

2

6

LONG 2, SHORT3

NOT ENABLED FOR LINCOLN PRODUCTS

LABELS:

NEGATIVE OUTPUT TERMINAL

FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE

POSITIVE OUTPUT TERMINAL

LONG 2, SHORT4

-50C WATER TEMPERATURE DETECTED

TYPICAL OCV (WARM MACHINE):

COMMON

LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY

88-98 VOLTS AT MAX RHEOSTAT

7

12

FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE

LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED

47-60 VOLTS AT MIN RHEOSTAT

FRAME GROUND

LATCH

LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK

UNDER LEFTDOOR

LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY

EARTH GROUND

VIEW OF CONNECTOR ON PC BOARD

LONG 2, SHORT 6

0 VOLTS DETECTED FROM "L" TERMINAL ON

BROKEN OR LOOSE BELT - INSPECT

ALTERNATOR FOR 1 SECOND

FAULTY ALTERNATOR - CHECK

PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

LONG 2, SHORT 7

OVER 18 VOLTS DETECTED FROM ALTERNATOR

INCORRECT BATTERY - INSPECT

TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

FAULTY ALTERNATOR - CHECK

UNLESS OTHERWISE SPECIFIED TOLERANCE

DESIGN INFORMATION

REFERENCE: EQUIPMENT TYPE:

PIPELINER 200D (KUBOTA V2203M)

MANUFACTURING TOLERANCE PER E2056

PAGE ___ OF ___

LESS THAN 4 VOLTS TO RPM SENSOR AND/OR

1

1

LONG 2, SHORT 8

ON 2 PLACE DECIMALS IS ± .02

DRAWN BY:

DM

L12020

ON 3 PLACE DECIMALS IS ± .002

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

ACTUATOR SENSED BY ECU

FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU

ON ALL ANGLES IS ± .5 OF A DEGREE

SUBJECT:

NUMBER:

REVISION:

MATERIAL TOLERANCE ("t") TO AGREE

ENGINEER:

J. STAPP

SCALE:

L12362

A

WITH PUBLISHED STANDARDS.

NA

MATERIAL

UF

APPROVAL

PROJECT

CRM35581

DO NOT SCALE THIS DRAWING

APPROVED:

DISPOSITION:

DATE:

08/04/2004

NUMBER:

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

PIPELINER® 200