Electrical diagrams, K924-5 remote control (optional), Pipeliner® 200 – Lincoln Electric PIPELINER 200 User Manual
Page 142
ELECTRICAL DIAGRAMS
G-8
PIPELINER® 200
SCHEMATIC - COMPLETE MACHINE - CODE 11114, 11316 - (L12362)
L12362
PIPELINER 200D (KUBOTA V2203M)
MACHINE SCHEMATIC
NA
L12020
DM
J. STAPP
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
WITH PUBLISHED STANDARDS.
MATERIAL TOLERANCE (" ") TO AGREE
t
DO NOT SCALE THIS DRAWING
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
L12362
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM35581
1
PAGE ___ OF ___
1
ENGINEERING CONTROLLED
MANUFACTURER:
No
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
A
08/04/2004
Released A.02 from X
CHANGE DETAIL:
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PC BOARD
1 2
6
7
12
LATCH
EX. 12 PIN CONNECTOR
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
K924-5 REMOTE CONTROL
(OPTIONAL)
RHEOSTAT
REMOTE CONTROL BOX
25+/-1.25 OHMS EACH
64+/-6.4 OHMS MAX
CCW
Y
W
G
X
REMOTE CONTROL PLUG
OIL PRESSURE SWITCH / SENDER
TEMPERATURE SWITCH / SENDER
W
G
TEMPERATURE
GAUGE
S
I
G
OIL PRESSURE
GAUGE
S
I
G
AMMETER
+
-
1
ENGINE
PROTECTION
LIGHT
ALTERNATOR
WK
G
TYPICAL CURRENT
DRAW IS 40 AMPS
+
HOUR METER
SWITCH CLOSES
AT 6+/-2 PSI
SENDER OPERATION:
0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
SWITCH CLOSES
AT 230
v
+/-6
v
F
SENDER OPERATION:
140
v
F -> 134+/-13.5 OHMS
194
v
F -> 51.2+/-4.3 OHMS
212
v
F -> 38.5+/-3 OHMS
COLOR: RED
12 VOLT
NORMALLY OFF
SHOWN IN "OFF"
POSITION
53
51C
50
50A
51
51A
212D
43
200
54
44
212A
212B
61
844A
841
844
-40 TO 40 AMPS
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
40 AMP / 12 VOLT
IG
B
L
GLOW PLUGS
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
LOCATED BEHIND UPPER LEFT
PORTION OF CONTROL PANEL
SENDER IS APPROX.
500 OHMS AT 70
v
F
1
2
3
WATER
TEMP.
SENSOR
ENGINE
SPEED
SENSOR
31
60F
19
58
6
IGNITION
SWITCH
212C
12
START
BUTTON
7
52A
52B
55
62
STARTER
RELAY
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
DOWN DUE TO A FAULT (EVEN IF THAT CONDITION
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF FUEL),
THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
4
87
86
88
11
2
3
10,000 +/- 1,000 OHMS MAX
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
60
SENSOR OPERATION:
-4
v
F -> 18.80 kOHMS
104
v
F -> 1.14 kOHMS
212
v
F -> .16 kOHMS
57
34
RATED VOLTAGE: 12V
RATED CURRENT: 2A
COIL RESISTENCE:
2.8 +/- .28 OHMS AT 20
v
C
ENERGIZED FOR RUN
DE-ENERGIZED FOR STOP
ACTUATOR CONTROLS RPM
MECHANICAL STOP WILL SHUT
DOWN THE ENGINE AT 115%
OF RATED SPEED.
27
28
841A
9
212E
26
64
16
15
51B
70A
70B
CONNECT TO
GROUND FOR
800RPM
CONNECT TO
GROUND FOR
1600RPM, LEAVE
UNCONNECTED
FOR 1800RPM
30
32
60E
ACTUATOR
56
18
69
13
60A
94
20
93
17
CCW
RPM CONTROL POTENTIOMETER
WIRE-TIED TO HARNESS
BEHIND CONTROL PANEL
OPEN LEAD IS WIRE-TIED INSIDE THE
HARNESS BEHIND CONTROL PANEL
SHOWN IN "AUTO
IDLE" POSITION
IDLER SWITCH
GND-B
841B
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
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
BROKEN OR LOOSE BELT - INSPECT
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
LONG 1, SHORT 5
FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
LONG 2, SHORT3
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
FAULTY ALTERNATOR - CHECK
INCORRECT BATTERY - INSPECT
FAULTY ALTERNATOR - CHECK
LONG 2, SHORT 8
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
ACTUATOR SENSED BY ECU
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
NOT ENABLED FOR LINCOLN PRODUCTS
NOT ENABLED FOR LINCOLN PRODUCTS
0 RPM IS DETECTED AND 12V IS DETECTED
FROM "L" TERMINAL ON ALTERNATOR
LONG 2, SHORT 1
LONG 1, SHORT 4
HIGH WATER TEMPERATURE DETECTED FOR 1
SECOND
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND
LONG 1, SHORT 3
"L" TERMINAL IS GROUNDED ON ALTERNATOR
FOR 1 SECOND
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
CURRENT TO ACTUATOR IS OUT OF LIMIT
LONG 2, SHORT 2
LONG 2, SHORT 6
0 VOLTS DETECTED FROM "L" TERMINAL ON
ALTERNATOR FOR 1 SECOND
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
-50C WATER TEMPERATURE DETECTED
LONG 2, SHORT4
12 VOLT SUPPLY
GLOW PLUG
BUTTON
+
BATTERY
STARTER
MOTOR
STARTER
SOLENOID
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
DC AUXILIARY
RECEPTACLE
NEGATIVE OUTPUT TERMINAL
POSITIVE OUTPUT TERMINAL
J3-4
J3-1
J3-3
J3-2
SERIES FIELD
SHUNT FIELD
-
+
GENERATOR LEAD BLOCK
SHOWN AS VIEWED WITH
ENGINE IN THIS DIRECTION
-
-
+
+
INTERPOLE
COILS
SHUNT
FIELD
SERIES FIELD
12 11 10 9 8 7 6 5 4 3 2 1
P10
J5
FJW-5AR COIL PAIR:
22.5+/-.5 OHMS EACH
FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
FDW-5M EXCITER COIL:
SHUNT COIL WINDINGS ARE 65+/-1.5 OHMS EACH
SERIES COIL WINDINGS ARE .143 +/-.005 OHMS EACH
SHOWN IN LOCAL
POSITION
Y
RHEOSTAT
W
G
X
REMOTE
RECEPTACLE
LOCAL / REMOTE
SWITCH
15 AMP
P9
J8
4
5
6 3
1
2
64+/-6.4 OHMS MAX
FUSE
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
+
_
N
U
67A
602B
720A
720C
602
730B
SELECTOR SWITCH
90-MIN
130-80
190-120
240-160
220-MAX
WELDING
GENERATOR
DC EXCITER
CCW
JUMPER PLUG IS
WIRE-TIED UP BEHIND
LOCAL / REMOTE
SWITCH ON RIGHT
SIDE OF MACHINE
DC EXCITER USES RESIDUAL
MAGNETISM TO FLASH
TYPICAL OCV (WARM MACHINE):
88-98 VOLTS AT MAX RHEOSTAT
47-60 VOLTS AT MIN RHEOSTAT
DRIVER
CIRCUITS
JUMPER PLUG IS
WIRE-TIED UP BEHIND
LOCAL / REMOTE
SWITCH ON RIGHT
SIDE OF MACHINE (AS
VIEWED FROM
CONTROL PANEL)
THESE LEADS MUST BE ROUTED THRU
CURRENT SENSOR IN SAME (CURRENT
FLOW) DIRECTION AS SHOWN
67B
610D
610C
610B
610
842
3 TURNS
730A
720B
N
U
602A
42
41
GND-T
70C
841B
BACK, BOTTOM
OF MACHINE
BACK, LEFT SIDE OF ENGINE
FRONT, LEFT SIDE OFENGINE
BACK, LEFT SIDE OF ENGINE
JUMPER PLUG IS BEHIND LOWER
RIGHTSIDE OFCONTROL PANEL
LOWER LEFT OF
CONTROL PANEL
LOWER LEFT OF
CONTROL PANEL
CENTER OF
CONTROL PANEL
BACK, RIGHT
SIDE OF ENGINE
BACK, LEFT
SIDE OF ENGINE
BACK, RIGHT
SIDE OF ENGINE
CENTER OF
CONTROL PANEL
UNDER LEFT DOOR
LOWER RIGHT OFCONTROL PANEL
LOWER LEFT OFCONTROL PANEL
ENGINE CONTROL UNIT (ECU)
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
RATED VOLTAGE: 12V
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
12 VOLT SUPPLY
THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE
PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT
DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
ECU CONNECTOR DETAIL
9
17
25
34
26
18
10
1
12 VOLT
SUPPLY
THE P10 PLUG IS ONLY ON UNITS WITHOUT
THE WIRE FEED MODULE. THE WIRE FEED
MODULE HAS A HARNESS THAT PLUGS
DIRECTLY INTO J5.
FLASHES ALTERNATOR
SENSES ALTERNATOR OUTPUT
SCHEMATIC S25973
CURRENT SENSING PC BOARD
G-8
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.