Lincoln Electric 200 service manual Schematic Complete Machine Code 11471 L13350

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G-9

ELECTRICAL DIAGRAMS

G-9

SCHEMATIC - COMPLETE MACHINE - CODE 11471 - (L13350)

L13350

ENGINEERING CONTROLLED

CHANGE DETAIL: New

MANUFACTURER:

No

JUMPER PLUG IS BEHIND LOWER

LOWER RIGHT OF CONTROL PANEL

12 VOLT SUPPLY

RIGHT SIDE OF CONTROL PANEL

RPM CONTROL POTENTIOMETER

AMMETER SHOWS FULL

K924-5 REMOTE CONTROL

94

20

11

87

1

10,000 +/- 1,000 OHMS MAX

GLOW PLUG

DISCHARGE WHILE PRESSING

GLOW PLUG SWITCH

RATED VOLTAGE: 12V

ENGINE

2

TURN POT COUNTERCLOCKWISE TO

BUTTON

(OPTIONAL)

ENGINE CONTROL UNIT (ECU)

86

2

SPEED

93

17

REDUCE RESISTANCE AND SUBSEQUENTLY

RATED CURRENT: 22mA MAX

CCW

53

GLOW PLUGS

SENSOR

LOCATED BEHIND UPPER PORTION OF CONTROL PANEL

3

88

REDUCE RPM BY UP TO 150RPM

3

BACK, RIGHT

60A

BACK, LEFT SIDE OF ENGINE

RATED VOLTAGE: 12V

4

51C

TYPICAL CURRENT

SIDE OF ENGINE

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

ALTERNATOR

DRAW IS 40 AMPS

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

40 AMP / 12 VOLT

26

64

L

69

13

REMOTE CONTROL PLUG

SENSOR OPERATION:

SENSES ALTERNATOR OUTPUT

IG

WATER

G

-4vF -> 18.80 kOHMS

B

TEMP.

FLASHES ALTERNATOR

104vF ->

1.14 kOHMS

212E

SENSOR

-40 TO 40 AMPS

212vF ->

.16 kOHMS

60

16

51B

Y

BACK, LEFT

IGNITION

51

AMMETER

BACK, BOTTOM

SIDE OF ENGINE

SWITCH

-

X

RATED VOLTAGE: 12V

1

9

15

212D

51A

50

STARTER

+

OF MACHINE

SHOWN IN "OFF"

+

RATED CURRENT: 2A

BACK, RIGHT

10

17

SOLENOID

BATTERY

COIL RESISTENCE:

57

34

18

FRONT , RIGHT SIDE

POSITION

W

25+/-1.25 OHMS EACH

25

2.8 +/- .28 OHMS AT 20vC

SIDE OF ENGINE

BACK, LEFT SIDE

STARTER

12.6 VOLTS MIN

ENERGIZED FOR RUN

12 VOLT

26

34

OF ENGINE

212A

DE-ENERGIZED FOR STOP

ACTUATOR

SUPPLY

28

44

OF ENGINE

43

S

I

841B

50A

MOTOR

AT REST

ACTUATOR CONTROLS RPM

14-14.5 VOLTS

G

TEMPERATURE

WHILE RUNNING

MECHANICAL STOP WILL SHUT

56

18

START

CCW

GAUGE

DOWN THE ENGINE AT 115%

TEMPERATURE SWITCH

TEMPERATURE

64+/-6.4 OHMS MAX

LOWER LEFT OF

BUTTON

OF RATED SPEED.

ECU CONNECTOR DETAIL

SENSOR

ENGINE

SWITCH CLOSES

SENDER OPERATION:

212B CONTROL PANEL

RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY

COLOR: RED

PROTECTION

61

9

THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING

AT 110v+/3vC

90vC -> 51.2+/-4.3 OHMS

62

OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED

12 VOLT

LIGHT

WHEN THE IGNITION SWITCH IS "ON" AND THE ECU

NORMALLY OFF

CENTER OF

841A

THE ENGINE PROTECTION LIGHT IN A CODED SEQUENCE,

FRONT, LEFT SIDE OF ENGINE

212C

SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT

RHEOSTAT

CONTROL PANEL

SEE CHART FOR FAULT CODES AND CORRECTIVE MEASURES.

S

I

OIL PRESSURE

DOWN DUE TO A FAULT (EVEN IF THAT CONDITION

WHEN THE ENGINE IS SHUT DOWN DUE TO A FAULT,

27

54

200

+

GAUGE

DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING

REMOTE CONTROL BOX

HOUR METER

58

6

THE IGNITION SWITCH WILL NEED TO BE TURNED OFF

WK

G

G

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

LOWER LEFT OF

52A

CENTER OF

THEN BACK ON TO RESTART THE ENGINE.

TURNED OFF THEN BACK ON TO RESTART THE ENGINE.

31

1

19

30

32

7

12

OIL PRESSURE SWITCH / SENDER

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

JUMPER PLUG IS

MODULE HAS A HARNESS THAT PLUGS

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 OF MACHINE (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 OF CONTROL 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 LEFT OF CONTROL 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 OF MACHINE

J3-3

W

U

15 AMP

REMOTE

N

12 VOLT SUPPLY

842

J3-2

RECEPTACLE

LOCAL / REMOTE

GENERATOR LEAD BLOCK

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

FJW-5AR COIL PAIR:

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

-

+

22.5+/-.5 OHMS EACH

LOW OIL - CHECK OIL LEVEL ON DIPSTICK

90-MIN

SHUNT

BRUSH POSITION

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

130-80

+

-

FIELD

SHOWN AS VIEWED

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

190-120

BROKEN OR LOOSE BELT - INSPECT

FROM CONTROL PANEL

"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

WELDING

COMPONENT VALUE UNITS:

FOR 1 SECOND

220-MAX

FAULTY ALTERNATOR - CHECK

COILS

GENERATOR

CAPACITOR: MFD/VOLTS

HIGH WATER TEMPERATURE DETECTED FOR 1

AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK

LONG 1, SHORT 4

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

SECOND

RESISTOR: OHMS/WATTS

LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK

LONG 1, SHORT 5

NOT ENABLED FOR LINCOLN PRODUCTS

CONNECTOR PIN NUMBERS:

LONG 2, SHORT 1

0 RPM IS DETECTED AND 12V IS DETECTED

FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION

_

FROM "L" TERMINAL ON ALTERNATOR

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

EX. 12 PIN CONNECTOR

FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE

+

LEAD COLOR CODE:

LONG 2, SHORT 2

CURRENT TO ACTUATOR IS OUT OF LIMIT

67A

LABELS:

1 2

6

LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK

B-BLACK OR GRAY

LONG 2, SHORT3

NOT ENABLED FOR LINCOLN PRODUCTS

NEGATIVE OUTPUT TERMINAL

G-GREEN

COMMON

FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE

POSITIVE OUTPUT TERMINAL

R-RED OR PINK

LONG 2, SHORT4

-50C WATER TEMPERATURE DETECTED

TYPICAL OCV (WARM MACHINE):

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

FRAME GROUND

88-98 VOLTS AT MAX RHEOSTAT

U-BLUE

7

12

FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE

LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED

47-60 VOLTS AT MIN RHEOSTAT

W-WHITE

EARTH GROUND

LATCH

LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK

UNDER LEFT DOOR

Y-YELLOW

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

VIEW OF CONNECTOR ON PC BOARD

0 VOLTS DETECTED FROM "L" TERMINAL ON

N-BROWN

LONG 2, SHORT 6

BROKEN OR LOOSE BELT - INSPECT

ALTERNATOR FOR 1 SECOND

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

FAULTY ALTERNATOR - CHECK

INCORRECT BATTERY - INSPECT

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

LONG 2, SHORT 7

OVER 18 VOLTS DETECTED FROM ALTERNATOR

MANUFACTURING TOLERANCE PER E2056

CONTROL: CLEVELAND

SCALE:

EQUIPMENT TYPE:

PIPELINER 200D KUBOTA

1

1

FAULTY ALTERNATOR - CHECK

UNLESS OTHERWISE SPECIFIED TOLERANCE:

LESS THAN 4 VOLTS TO RPM SENSOR AND/OR

ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)

DRAWN BY:

Maglietta

NONE

PAGE ___ OF ___

LONG 2, SHORT 8

ACTUATOR SENSED BY ECU

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

ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)

IF PRINTED

SUBJECT:

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

ON ALL ANGLES IS ± .5 OF A DEGREE

ENGINEER:

D. BENDER

@ A2 SIZE

NUMBER:

REVISION:

MATERIAL TOLERANCE ("t") TO AGREE

UNITS:

L13350

A

WITH PUBLISHED STANDARDS.

MATERIAL

NA

APPROVAL

11/16/2007

PROJECT

CRM37569

REFERENCE:

DO NOT SCALE THIS DRAWING

APPROVED:

-

INCH

DISPOSITION:

DATE:

NUMBER:

L12362

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

PIPELINER® 200