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Lincoln Electric service manual AA-1, Pipeliner 200D Perkins

Models: 200

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AA-1

TABLE OF CONTENTS - INSTALLATION SECTION

AA-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AA-1

Technical Specifications	.AA-2
Safety Precautions	.AA-3
Trailers, Polarity Control & Cable Sizes	.AA-4
Oil, Fuel, Cooling System & Battery Charging	.AA-5

PIPELINER® 200D PERKINS

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Lincoln Electric service manual AA-1, Pipeliner 200D Perkins

Contents

Pipeliner For Engine SafetyElectric Magnetic Fields PipelinerFumes and Gases Electric Shock can kill ARC Rays can burnIii For ElectricallyPrécautions DE Sûreté Pour Précautions DE SûretéLES Machines À Souder À Transformateur ET ÀMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Pipeliner 200D Kubota K6090-11 InstallationHeight Width Depth Weight Description Rated DC OutputGeneral Description Design FeaturesMachine Grounding PRE-OPERATION InstallationExhaust Spark Arrester Lift BailTrailer PRE-OPERATION ServiceOIL Fuel Polarity Control and Cable SizesBattery Charging Warning Table of Contents Operation Section Engine Operation OperationEngine BREAK-IN Duty Cycle Welder OperationControl of Welding Current Do not Turn the Current Range SelecIdler Operation Typical Fuel Consumption DataTable of Contents Accessories Section Wire Feed Options AccessoriesWire Feed Module K623-1 Provides constant LN-15 Wire Feeder K1870-1,-2-Portable CC/CV unitTable of Contents Maintenance Section Safety Precautions MaintenancePurging AIR from Fuel System Idler MaintenanceKubota V2203M Engine NameplatesEngine Service Figure D.2 Major Component Location Pipeliner 200D Kubota Pipeliner 200D Perkins AA-1Lubrication Fuel System Governor AIR Cleaner Engine Idler Muffler Engine ProtectionFalling Location / VentilationRead the engine operating and maintenance PRE-OPERATION ServiceAA-4 Vehicle MountingwarningAA-5 Battery ChargingGround Pipeliner 200D Perkins AA-6 BB-1 Rated Output Duty Cycle Diesel Engine Cold Weather StartingStarting the Pipeliner 200D Perkins Control of Welding Current Duty CycleBB-4 Idler Operation Auxiliary PowerBB-5 BB-6 CC-1 Remote Control Kit K2464-1 Contains a remote Optional FeaturesCC-2 DD-1 General Instructions Engine MaintenanceCommutator and Brushes Bearings Idler MaintenanceVent Screw DD-4DD-5 Figure DD.2 Major Component LocationDD-6 AAA-1TABLE of Contents Installation Section AAA-1 Description Rated DC Output Duty Cycle DC Current Range AAA-2AAA-3 AAA-4 Angle of OperationFuel GasolinePipeliner 200G AAA-6 BBB-1 BBB-2 Safety Precautions Design SummaryIgnition System Stopping the Engine High Idle RPM OCV AdjustmentStarting the GM 3.0L Engine BBB-3TBI Deicing System Control of Welding Current Idler OperationBBB-4 CCC-1TABLE of Contents Accessories Section CCC-1 Accessories DDD-1TABLE of Contents Maintenance Section DDD-1 Guards off Stop engine before servicing DDD-2DDD-3 Bearings Idle Control MaintenanceDDD-4 Engine ServiceDDD-5 Figure DDD.1 Major Component LocationPipeliner 200G DDD-6 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationFigure E.3 Engine Control Figure E.4 Engine Control Figure E.5 Engine Control Frame and DC Exciter ENGINE, Main Generator ArmatureFigure E.7 DC Generator Theory DC Generator MachinesPipeliner 1TABLE of Contents Troubleshooting & Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock PC Board Troubleshooting ProceduresShunt Field Winding Test Troubleshooting & Repair Only Test. Perkins Receptacle. When the engine is Board Test. Replace if Oil Kubota EUC Codes Pipeliner DC Exciter Test 13TROUBLESHOOTING & REPAIRF-13Test Description Test Procedure 14TROUBLESHOOTING & REPAIRF-14Figure F.2 Exciter Cover Removal 15TROUBLESHOOTING & REPAIRF-15Shunt Coil and Series Coil Resistance Tests 16TROUBLESHOOTING & REPAIRF-16Idler Solenoid Test 17TROUBLESHOOTING & REPAIRF-17Materials Needed Quick Connect Leads Test ProcedureMain Generator Shunt Field Winding Test 19TROUBLESHOOTING & REPAIRF-19Main Generator Shunt Field Winding Test 20TROUBLESHOOTING & REPAIRF-20Figure F.6 Plug P10 PIN Assignments TAB 21TROUBLESHOOTING & REPAIRF-21Pipeliner Flashing the Fields 23TROUBLESHOOTING & REPAIRF-23Figure F.7 Exciter Cover Removal Exiter ProcedureRaise To Negative To Positive Battery TerminalExciter Brush OFFPipeliner Engine Alternator Test 27TROUBLESHOOTING & REPAIRF-27Test Procedure 28TROUBLESHOOTING & REPAIRF-28OIL Pressure Temperature Switch Test 29TROUBLESHOOTING & REPAIRF-29Procedure 30TROUBLESHOOTING & REPAIRF-30Return to Return to Section TOC Pipeliner Current Sensor PCB Test 33TROUBLESHOOTING & REPAIRF-33Figure F.11 Case Covers 34TROUBLESHOOTING & REPAIRF-34Figure F.12 Current Sensing PCB Pipeliner 35TROUBLESHOOTING & REPAIRF-35Pipeliner Engine Throttle Adjustment Test Perkins only 37TROUBLESHOOTING & REPAIRF-37Figure F.13 Blower Paddle Mark Location 38TROUBLESHOOTING & REPAIRF-38Engine Throttle Adjustment Test 39TROUBLESHOOTING & REPAIRF-39Perkins only Scope Settings 41TROUBLESHOOTING & REPAIRF-41Normal Open Circuit DC Weld Voltage Waveform 42TROUBLESHOOTING & REPAIRF-42Machine Loaded Selector Switch AT Maximum 43TROUBLESHOOTING & REPAIRF-43Typical DC Weld Voltage Waveform Pipeliner Description 45TROUBLESHOOTING & REPAIRF-45Reassembly 46TROUBLESHOOTING & REPAIRF-46DC Exciter Armature & Field Coils Field Coils Removal Procedure ReassemblyPipeliner Main Generator Frame Removal and Replacement Procedure 49TROUBLESHOOTING & REPAIRF-49Figure F.16 Battery Panel Removal 50TROUBLESHOOTING & REPAIRF-50Bolt / NUT 51TROUBLESHOOTING & REPAIRF-51Door Hooks Fuel Bowl Rails 52TROUBLESHOOTING & REPAIRF-52Lead 53TROUBLESHOOTING & REPAIRF-53Figure F.21 Choke Control Cable Removal Loosen Here 54TROUBLESHOOTING & REPAIRF-54Shunt Leads DC Receptacle Quick Disconnect 55TROUBLESHOOTING & REPAIRF-5556TROUBLESHOOTING & REPAIRF-56 57TROUBLESHOOTING & REPAIRF-57 Feet 58TROUBLESHOOTING & REPAIRF-58Remove Mounting NUTS, Washers Bolts Main Generator Frame Removal and Replacement Procedure Pipeliner Main Generator Armature Removal and Replacement Procedure 61TROUBLESHOOTING & REPAIRF-61Armature is now free to be removed from the engine 62TROUBLESHOOTING & REPAIRF-62Sling Blower Paddle Mounting Bolts Lock Washers RPM Welder DC OutputPipeliner Table of Contents Diagram Section Electrical Diagrams Wiring DiagramWiring Diagram Wiring Diagram Pipeliner 200D Wiring Diagram Wiring Diagram Code 11471 M21564 L12020 Schematic -COMPLETE Machine Code 10929 L12020L12362 OptionalL13350 Schematic Complete Machine Code 11471 L13350S25973 Schematic IDLER/ENGINE Shutdown Code 10929 L10826