Lincoln Electric 200 Welder User Manual


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ELECTRICAL DIAGRAMS
G-9
PIPELINER® 200
SCHEMATIC - COMPLETE MACHINE - CODE 11471 - (L13350)
L13350
PIP
EL
INE
R 200
D K
UBOTA
MA
C
HI
NE SC
HE
MATI
C
NONE
L12362
DO NOT
SCAL
E
T
HIS DR
A
WING
EQU
IPM
ENT
TYPE
:
SUB
JECT
:
NA
CRM
37569
1
PAG
E
___
OF
___
1
EN
GIN
E
ERIN
G CON
T
RO
LL
ED
M
ANUF
AC
T
URER:
No
T
HIS
DOCUM
EN
T
CON
T
AIN
S
PR
O
PRI
ET
ARY IN
FO
RMA
T
ION
OW
NE
D BY
L
INCO
L
N G
LOBAL
, INC.
AN
D MAY N
OT
B
E D
UP
L
ICA
T
ED,
COMMUNIC
AT
ED
T
O
OT
HE
R P
AR
T
IES
OR U
S
ED
FO
R A
NY PUR
POS
E
WIT
HOU
TT
HE
EXPR
ES
S
W
RI
TT
EN
P
ERMI
S
SI
ON
OF
L
INCO
L
N G
LOBAL
, INC.
PROP
RI
ETARY
&
CO
NFI
DENT
IAL:
Ne
w
t
MATE
RIA
L
TOLERA
NC
E
("
") T
O
A
GR
EE
WI
T
H PU
B
LI
SHE
D S
TA
ND
A
RD
S.
ON
AL
L
A
NG
LE
S I
S ± .
5
O
F
A D
E
GR
EE
ON
3
PLACE DECIMALS IS
±
.0
02
in
.(
±
0.05
mm)
ON
2
PLAC
E D
E
CIM
AL
S I
S ± .
0
2 i
n. (
±
0.
5
mm)
UN
LESS
OT
HE
RW
ISE
SPE
CIF
IE
DTO
LE
RA
N
CE
:
MA
NU
FACT
URING
TOLERA
NC
E
PE
R E
2056
CHANGE
DET
AIL:
REFERENCE:
SC
ALE:
MAT
ER
IAL
DI
SPOSITI
ON:
AP
PR
OVAL
DA
TE:
PR
OJ
EC
T
NUMB
ER
:
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
UNIT
S:
IF PRINTED
@A2SIZE
INCH
11/16/2007
Ma
gli
etta
D.
B
END
ER
-
DRAW
N
B
Y:
ENG
IN
EE
R:
CL
EVEL
AND
APPROVE
D:
CONTRO
L:
A
L13350
EA
RT
H GROUND
FR
AME GROUND
C
OMMO
N
LABELS:
E
X. 12
PIN CONNECTOR
LAT
CH
127
6
2
1
VI
E
W OF CONNECTOR ON PC BO
ARD
CONNE
CT
OR PIN N
UM
BERS:
RESIS
TO
R: O
HM
S/WA
TTS
CAPAC
ITO
R:
MF
D/V
OLT
S
C
OM
PONE
NT
VALUE UN
IT
S:
B-BLACK OR GRAY
G-G
REEN
R-RED OR PINK
U-BLUE
W-WH
IT
E
Y-YE
LLO
W
N-BROWN
L
EAD C
OL
ORCODE:
K924-5 REMOTE CONTROL
(OPTIONAL)
RHEOSTAT
RE
MOT
E CO
NT
R
OL
BOX
2
5+/-1.
25
OH
M
S
E
ACH
6
4+/-6.
4
OH
M
S
MAX
CCW
Y
W
G
X
RE
MOT
ECO
NT
R
OL
PLUG
OIL
PRESSUR
E
S
WITC
H / S
ENDER
TE
MPER
AT
UR
E
S
WITC
H
TE
MPER
AT
URE
GAUGE
S
I
G
OIL
PRESSURE
GAUGE
SI
G
A
MM
ET
ER
+
-
1
EN
GI
NE
PR
OT
E
CTIO
N
LIG
HT
A
LT
ERN
AT
OR
WK
G
TY
PI
CA
L C
URRE
NT
DRA
W I
S
40
AMPS
+
HOU
R M
ET
ER
S
WITC
H C
LOSES
AT
6+/-2
P
SI
SENDE
R
OPER
ATI
O
N:
0
P
SI ->
10
+/-5 O
HM
S
40
P
SI ->
10
5+/-5
O
HM
S
80
P
SI ->
18
7+/-5
O
HM
S
SENSO
R
GROUND
S
LEAD
O
N
SENS
E
OF
WE
LD
OR
AU
XI
LI
AR
Y
LOAD
S
WITC
H C
LOSES
AT
11
0v
+/3
vC
SENDE
R
OPER
ATI
O
N:
90
v
C -> 5
1.2+/-4.
3 O
HM
S
COLO
R: R
ED
12
VO
LT
NO
RM
A
LL
Y
OFF
SHOW
N IN "OFF"
PO
SITI
ON
53
51
C
50
50
A
51
51
A
21
2D
43
20
0
54
44
21
2A
21
2B
61
84
4A
84
1
84
4
-40 T
O 4
0
AMPS
A
MM
ET
E
R
SHOW
S F
UL
L
DI
SCHARG
E
W
HIL
E
PRES
SI
NG
GLO
W
P
LU
G
S
WITC
H
40
AM
P / 1
2
VO
LT
IG
B
L
GLO
W
P
LU
GS
12.6
VO
LT
S
MIN
AT
RE
ST
14-
14.5
VO
LT
S
W
HIL
E
RUN
NIN
G
LOC
AT
E
D
BE
HIND U
PPE
R L
EFT
PO
RTIO
N
OF C
O
NTR
O
L
PANEL
1
2
3
W
AT
ER
TE
M
P.
SENSOR
EN
GI
NE
SPEED
SENSOR
31
60F
19
58
6
IG
NITIO
N
S
WITC
H
21
2C
12
ST
A
RT
B
UTTO
N
7
52
A
52
B
55
62
ST
A
RT
ER
RELAY
RELA
Y
CO
NT
A
CT
S F
O
R 5
2
AN
D 5
2
A
AR
E
NO
RM
A
LL
Y
OPE
N. TH
E
ST
A
RT
E
R M
OT
O
R C
A
N
O
NL
Y
B
E
ENGAGED
WHE
N TH
E I
G
NITIO
N
S
WITC
H I
S "
O
N"
AN
D TH
E
ECU
SENSE
S
LES
S T
HA
N 7
00
RP
M.
IF
TH
E
EN
GI
N
E I
S
SH
UT
DOW
N D
U
E T
O
A F
A
ULT
(EV
EN
IF T
HA
TCO
ND
ITION
DOES NOT
RESU
LT INA FLA
SH
CO
DE
,
SU
CH
AS
RUNN
ING
OUT OF F
UE
L),
TH
E I
G
NITIO
N
S
WITC
H
WI
LL
NEE
D TO
BE
TUR
NE
D
OFF TH
E
N
BAC
K
O
N TO
RE
ST
A
RT TH
E
EN
GI
N
E.
4
87
86
88
11
2
3
10,0
00 +/- 1,0
00
O
HM
S
MAX
TUR
N
P
OT C
OU
NT
ER
CL
OCK
WI
S
E T
O
REDUC
E
RE
SI
ST
ANC
E
AN
D
SUBSEQUE
NTL
Y
REDUC
E
RP
M
B
Y
U
P T
O 1
50
RPM
R
AT
E
D
VO
LT
AG
E:
12
V
R
AT
E
D C
URRE
NT: 22m
A
MAX
60
SE
NSO
R OPE
RATION:
-4
v
F
-> 1
8.
8
0 kOHMS
104v
F ->
1.
1
4 kOHMS
212v
F ->
.
1
6 kOHMS
57 34
RATE
D VOLTAGE: 1
2V
RATE
D
CUR
RE
NT: 2A
COIL RESISTE
N
CE:
2.8
+/- .
2
8 OHMS AT 2
0vC
EN
ERGIZE
D FOR
RUN
DE
-E
NE
RGIZE
D FOR STOP
ACT
UATO
RCO
NT
ROLS RP
M
ME
C
HA
NI
CAL STOP WI
L
L SHUT
DOWN TH
E ENGI
NE AT 11
5%
OF RATE
D SP
EE
D.
27
28
84
1A
9
21
2E
26
64
16
15
51
B
70
A
70
B
CONNE
CT TO
GROUN
D FO
R
80
0R
PM
CONNE
CT TO
GROUN
D FO
R
1600
RP
M, L
EAVE
UNCONNE
CT
ED
FO
R 1
80
0R
PM
30
32
60
E
A
CTU
AT
OR
56 18
6913
60
A
94 20
9317
CCW
RP
M C
O
NTR
O
L
P
OT
E
NTIOM
ET
ER
WI
RE
-TIE
D TO
HARNESS
BE
HIND C
O
NTR
O
L
PANEL
OPE
N L
EA
D I
S
WI
RE
-TIE
D IN
SI
D
E T
HE
HARNES
S
BE
HIND C
O
NTR
O
L
PANEL
SHOW
N IN "
A
UT
O
IDL
E
" P
O
SITI
ON
IDL
E
R
S
WITC
H
GN
D-
B
84
1B
LIGHTCODE FAILUREDETECTED POSSIBLECAUSE-CORRECTIVEMEASURE
LONG1, SHORT 1 RPMIS OVER 115% OF RATED RPM(2070 RPM) ACTUATOR IS STUCK -REMOVE ACTUATORAND VERIFYPLUNGERPULLS INWHEN ENERGIZED
LOW OIL - CHECK OIL LEVELON DIPSTICK
FAULTYOIL PRESSURE SWITCH -CHECK THAT"WK" STUD IS OPENWHENENGINE IS RUNNING
LEAD TOOIL PRESSURE SWITCH "WK" STUD MAYBEGROUNDED - CHECK
BROKEN OR LOOSEBELT - INSPECT
LEAD TO"L" TERMINAL ON ALTERNATORMAY BESHORTED TO GROUND - CHECK
FAULTY ALTERNATOR- CHECK
AMOUNT OR QUALITY OFCOOLANTINCORRECT -CHECK
FAULTYWATER TEMPERATURE SWITCH - CHECK THAT"WK" STUD ISOPEN WHENENGINE IS NOTRUNNING
LEAD TOWATER TEMPERATURE SWITCH MAY BEGROUNDED - CHECK
LONG1, SHORT5
FAULTYRPMSENSOR - CHECKFORGOOD CONNECTION
FAULTYECU -CHECK FOR12VOLTS ONSUPPLY LEAD TO RPM SENSORFROMECU
FAULTYACTUATOR-CHECKFOR PROPERCOIL RESISTANCE
LEADS TOACTUATORMAY BEOPEN OR GROUNDED - CHECK
LONG 2, SHORT3
FAULTYWATER TEMPERATURE SENSO
R-CHECK FORPROPER RESISTANCE
LEAD TOWATER TEMPERATURE SENSORMAYBEOPEN - CHECKFORCONTINUITY
FAULTYWATER TEMPERATURE SENSOR -CHECK FORPROPER RESISTANCE
LEAD TOWATER TEMPERATURE SENSORMAYBEGROUNDED -CHECK
LEAD TO"L" TERMINAL ON ALTERNATORMAY BEOPEN - CHECKFOR CONTINUITY
BROKEN OR LOOSEBELT - INSPECT
FAULTYALTERNATOR-CHECK
INCORRECTBATTERY-INSPECT
FAULTYALTERNATOR-CHECK
LONG2, SHORT8
LESS THAN4VOLTS TORPMSENSOR AND/OR
ACTUATORSENSED BYECU FAULTYECU -CHECK FOR12 VOLTS ON LEADS TORPM SENSORAND ACTUATOR FROM ECU
NOT ENABLED FOR LINCOLNPRODUCTS
NOT ENABLED FOR LINCOLNPRODUCTS
0 RPMIS DETECTED AND 12VIS DETECTED
FROM"L" TERMINAL ONALTERNATOR
LONG2, SHORT1
LONG1, SHORT4
HIGH WATER TEMPERATURE DETECTED FOR 1
SECOND
LONG1, SHORT 2 LOW OILPRESSURE DETECTED FOR 1 SECOND
LONG1, SHORT3
"L" TERMINALIS GROUNDED ON ALTERNATOR
FOR 1 SECOND
LONG2, SHORT 7 OVER18 VOLTS DETECTED FROMALTERNATOR
CURRENT TO ACTUATOR IS OUT OF LIMITLO
NG 2, SHORT 2
LONG2, SHORT6
0 VOLTS DETECTED FROM"L" TERMINAL ON
ALTERNATOR FOR1SECOND
LONG2, SHORT 5 150C WATER TEMPERATUREDETECTED
-50CWATER TEMPERATURE DETECTEDLONG 2, SHORT4
1
2 VO
LT SUP
PLY
GLO
W
P
LU
G
B
UTTO
N
+
B
ATT
ERY
ST
A
RT
ER
MOT
OR
ST
A
RT
ER
SOLEN
OI
D
BRUS
H
PO
SITI
O
N
SHOW
N
AS
VI
EWE
D FR
OM
CO
NTR
O
L
PANEL
D
C
AU
XI
LI
ARY
RECE
PT
A
CL
E
NEG
ATI
V
E
O
UT
P
UT TE
RMIN
AL
PO
SITI
V
E
O
UT
P
UT TE
RMIN
AL
J3-4
J3-1
J3-3
J3-2
SE
RI
E
S FI
E
LD
SHU
NT FIE
LD
-
+
GEN
ER
ATOR LEAD BLOC
K
SHOWN A
S VIEWED WITH
ENGI
NE I
N THIS
DI
RE
CTION
-
-
+
+
INT
ERPOLE
C
OIL
S
SHU
NT
FIE
LD
SE
RI
E
S FI
E
LD
12 11 10
9
8
7
65
4
3
2
1
P
10
J5
FJW-
5A
R C
OIL
P
AI
R:
22.5
+/-.5 O
HM
S
EACH
FL
YBAC
K
DI
OD
E
PREVE
NT
S
VO
LT
AG
E
S
PI
KE
S I
N
SHU
NT FIE
LD
FR
OM
DAMA
GI
N
G L
OCA
L/R
E
MOT
E
TO
GGL
E
S
WITC
H
WHE
N
S
WITC
HED
FD
W-
5M
EX
CIT
E
R C
OIL:
SHU
NT C
OIL
WI
N
DIN
G
S
AR
E
65
+/-1.5
O
HM
S
EACH
SE
RI
E
S
C
OIL
WI
N
DIN
G
S
AR
E .
14
3 +/-.00
5 O
HM
S
EACH
SHOW
N IN L
OCAL
PO
SITI
ON
Y
RHEO
STAT
W
G
X
RE
MOT
E
RECE
PT
A
CL
E
LOCA
L / R
E
MOT
E
S
WITC
H
15
AMP
P9
J8
45631 2
64
+/-6.4
O
HM
S
MAX
FU
SE
BRUS
H
PO
SITI
ON
SHOW
N
A
SVI
EWED
FR
OM
CO
NTR
O
L
PANEL
+
_
N
U
67
A
60
2B
72
0A
72
0C
60
2
73
0B
SELE
CT
O
R
S
WITC
H
90-MI
N
13
0-8
0
19
0-1
20
24
0-1
60
22
0-M
AX
WELDING
GENERATOR
DC EXCITER
CCW
JUM
PE
R
P
LU
G I
S
WI
RE
-TIE
D U
P
BE
HIN
D
LOCA
L / R
E
MOT
E
S
WITC
H
O
N RI
G
HT
SI
D
E
OF M
AC
HIN
E
D
C
EX
CIT
E
R U
SE
S
RE
SI
DUAL
MAGN
ETI
S
M TO FL
ASH
TY
PI
CA
L O
C
V (
WA
RM M
AC
HIN
E
):
88-9
8
VO
LT
S
AT M
A
X
RHEO
STAT
47-6
0
VO
LT
S
AT MI
N R
HEO
STAT
D
RI
VER
CIR
C
UIT
S
JUM
PE
R
P
LU
G I
S
WI
RE
-TIE
D U
P
BE
HIN
D
LOCA
L / R
E
MOT
E
S
WITC
H
O
N RI
G
HT
SI
D
E
OF M
AC
HIN
E (
AS
VI
EWE
D FR
OM
CO
NTR
O
L
PANE
L)
THES
E LEADS M
UST BE
RO
UTE
D TH
RU
CUR
RE
NT SE
NSO
R IN SA
ME (
CUR
RE
NT
FLO
W) DIRE
CTION AS S
HOWN
67
B
61
0D
61
0C
61
0B
61
0
84
2
3
TU
R
NS
73
0A
72
0B
N
U
60
2A
42
41
GN
D-T
70
C
84
1B
BAC
K,
B
OTT
OM
OF M
AC
HIN
E
FRO
NT , RIG
HT
SI
DE
OF
EN
GI
NE
FRO
NT, L
EFT
SI
D
E
OF
EN
GI
NE
B
AC
K,
L
EFT
SI
D
E
OF
EN
GI
NE
JUM
PE
R
P
LU
G I
S
BE
HIN
D L
OWER
RI
G
HT
SI
D
E
OF C
O
NTR
O
L
PANEL
LO
WE
R L
EFT
OF
CO
NTR
O
L
PANEL
LO
WE
R L
EFT
OF
CO
NTR
O
L
PANEL
CE
NT
E
R
OF
CO
NTR
O
L
PANEL
B
AC
K,
RI
G
HT
SI
D
E
OF
EN
GI
NE
B
AC
K,
L
EFT
SI
D
E
OF
EN
GI
NE
B
AC
K,
RI
G
HT
SI
D
E
OF
EN
GI
NE
CE
NT
E
R
OF
CO
NTR
O
L
PANEL
UN
DE
R L
EFT D
OOR
LO
WE
R RI
G
HT OF C
O
NTR
O
L
PANEL
LO
WE
R L
EFT
OF C
O
NTR
O
L
PANEL
ENGINE CONTROL UNIT (ECU)
LOC
AT
E
D
BE
HIND U
PPE
R
PO
RTIO
N
OF C
O
NTR
O
L
PANEL
R
AT
E
D
VO
LT
AG
E: 1
2V
R
AT
E
D C
URRE
NT: 4.5
A
(M
A
X.)-T
E
RMIN
A
L
#
15
LEAKAG
E
CURRE
NT 10m
icro
A (
MA
X.)-T
E
RMIN
A
L
#
16
1
2 VO
LT SUP
PLY
THE E
C
U WIL
L
INDI
CATE FA
ULT CON
DITIONS BY FLASHING
THE E
NGI
NE P
ROTE
CTION LIGHT IN A CO
DE
D SEQ
UE
N
CE,
SEE
C
HA
RT FOR FA
ULT COD
ES A
N
DCO
R
RE
CTIVE ME
AS
U
RE
S.
WHEN T
HE E
NGI
NE IS S
H
UT DOWN
D
UE TO A FAULT,
THE IGNITION SWITCH WIL
L NEED TO BE TU
R
NE
D OFF
THE
N BA
CK O
N TO RESTA
RT THE E
NGI
NE.
EC
U C
ONNE
CT
O
R D
ET
AI
L
9
17
25
34
26
18
10
1
1
2 VO
LT
SU
PPLY
THE P10 P
LUG IS ONLY
ON U
NITS WITHOUT
THE WIRE FEE
D MO
D
ULE. THE WIRE FEED
MO
D
ULE HA
S A HA
R
NE
SS THAT PLUGS
DI
RE
CTLY
INTO J5.
FLASHES ALTER
NATO
R
SE
NSES ALTERNATO
R O
UTP
UT
SCHEM
ATI
C
S
2597
3
CURREN
T
SENSING PC BOARD
B
AC
K,
L
EFT
SI
DE
OF
EN
GI
NE
TE
MPER
AT
URE
SENSOR
G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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