Electrical diagrams, K924-5 remote control (optional), Pipeliner® 200 – Lincoln Electric PIPELINER 200 User Manual

Page 143: Pipeliner 200d kubota machine schematic

ELECTRICAL DIAGRAMS

G-9

PIPELINER® 200

SCHEMATIC - COMPLETE MACHINE - CODE 11471 - (L13350)

L13350

PIPELINER 200D KUBOTA

MACHINE SCHEMATIC

NONE

L12362

DO NOT SCALE THIS DRAWING

EQUIPMENT TYPE:

SUBJECT:

CRM37569

PAGE ___ OF ___

ENGINEERING CONTROLLED
MANUFACTURER:

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:

New

MATERIAL TOLERANCE (" ") TO AGREE

WITH PUBLISHED STANDARDS.

ON ALL ANGLES IS ± .5 OF A DEGREE

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

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

UNLESS OTHERWISE SPECIFIED TOLERANCE:

MANUFACTURING TOLERANCE PER E2056

CHANGE DETAIL:

REFERENCE:

SCALE:

MATERIAL
DISPOSITION:

APPROVAL
DATE:

PROJECT
NUMBER:

DOCUMENT
NUMBER:

DOCUMENT
REVISION:

UNITS:

IF PRINTED

@ A2 SIZE

INCH

11/16/2007

Maglietta

D. BENDER

DRAWN BY:

ENGINEER:

CLEVELAND

APPROVED:

CONTROL:

L133

EARTH GROUND

FRAME GROUND

COMMON

LABELS:

EX. 12 PIN CONNECTOR

LATCH

VIEW OF CONNECTOR ON PC BOARD

CONNECTOR PIN NUMBERS:

RESISTOR: OHMS/WATTS

CAPACITOR: MFD/VOLTS

COMPONENT VALUE UNITS:

B-BLACK OR GRAY

G-GREEN
R-RED OR PINK

U-BLUE
W-WHITE

Y-YELLOW

N-BROWN

LEAD COLOR CODE:

K924-5 REMOTE CONTROL

(OPTIONAL)

RHEOSTAT

REMOTE CONTROL BOX

25+/-1.25 OHMS EACH

64+/-6.4 OHMS MAX

CCW

REMOTE CONTROL PLUG

OIL PRESSURE SWITCH / SENDER

TEMPERATURE SWITCH

TEMPERATURE

GAUGE

OIL PRESSURE

GAUGE

AMMETER

ENGINE

PROTECTION
LIGHT

ALTERNATOR

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 110

+/3

SENDER OPERATION:

C -> 51.2+/-4.3 OHMS

COLOR: RED
12 VOLT
NORMALLY OFF

SHOWN IN "OFF"

POSITION

51C

50A

51A

212D

200

212A

212B

844A

841

844

-40 TO 40 AMPS

AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING

GLOW PLUG SWITCH

40 AMP / 12 VOLT

IG
B

GLOW PLUGS

12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING

LOCATED BEHIND UPPER LEFT

PORTION OF CONTROL PANEL

WATER
TEMP.
SENSOR

ENGINE
SPEED
SENSOR

60F

IGNITION
SWITCH

212C

START

BUTTON

52A

52B

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.

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

SENSOR OPERATION:
-4

-> 18.80 kOHMS

104

F ->

1.14 kOHMS

212

F ->

.16 kOHMS

RATED VOLTAGE: 12V
RATED CURRENT: 2A
COIL RESISTENCE:

2.8 +/- .28 OHMS AT 20

ENERGIZED FOR RUN
DE-ENERGIZED FOR STOP
ACTUATOR CONTROLS RPM
MECHANICAL STOP WILL SHUT
DOWN THE ENGINE AT 115%
OF RATED SPEED.

841A

212E

51B

70A

70B

CONNECT TO
GROUND FOR
800RPM

CONNECT TO
GROUND FOR
1600RPM, LEAVE
UNCONNECTED
FOR 1800RPM

60E

ACTUATOR

60A

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

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

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

RHEOSTAT

REMOTE

RECEPTACLE

LOCAL / REMOTE
SWITCH

15 AMP

6 3

64+/-6.4 OHMS MAX

FUSE

BRUSH POSITION
SHOWN AS VIEWED
FROM CONTROL PANEL

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

602A

GND-T

70C

841B

BACK, BOTTOM

OF MACHINE

FRONT , RIGHT SIDE

OF ENGINE

FRONT, LEFT SIDE OF ENGINE

BACK, LEFT SIDE OF ENGINE

JUMPER PLUG IS BEHIND LOWER

RIGHT SIDE OF CONTROL 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 OF CONTROL PANEL

LOWER LEFT OF CONTROL 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

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

BACK, LEFT SIDE

OF ENGINE

TEMPERATURE

SENSOR