Lincoln Electric 200 instruction

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F-1TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide	. . . .F-2
PC Board Troubleshooting Procedures	. . . .F-3
Troubleshooting Guide	. . . .F-4
Test Procedures	. . .F-13
DC Exciter Test	. . .F-13
Idler Solenoid Test	. . .F-17
Main Generator Test	. . .F-19
Flashing The Fields	. . F-23
Engine Alternator Test	. . .F-27
Oil Pressure - Temp. Switch Test	. . .F-29
Current Sensor PCB Test	. . .F-33
Engine Throttle Adjustment Test (Perkins Only)	. . .F-37
Waveforms	F-41/43
Removal & Replacement Procedures	. . .F-45
DC Armature & Field Coils	. . .F-45
Main Generator Frame	. . .F-49
Main Generator Armature	. . .F-61
Retest and Repair	. . .F-63

PIPELINER® 200

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Lincoln Electric 200 service manual 1TABLE of Contents Troubleshooting & Repair F-1

Contents

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