Lincoln Electric PIPELINER 200D KUBOTA User manual

Pipeliner®200D
Publication E6.132 4/05
Web Update 5/08
.lincolnelectric.com
TECHNICAL SPECIFICATIONS
ENGINE DRIVEN WELDERS
(1)
No. Dimensions
Product Rated Output Output Engine of HP & Speed H x W x D Net Weight
Name Current/Voltage/Duty Cycle Range Model Cyl. (rpm) inches (mm) lbs (kg)
Pipeliner®200D 200A DC/40V/60% 40-300 DC Kubota®4 27.8 @ 1600 45.5 x 24.0 x 68.0 1311
1750 watts V2403M (1156 x 610 x 1727) (595)
DC Auxiliary Power EPA Tier 4i
120V DC
(1) With Wire Feed Module. Rated at 200 amps, 35 volts at 60% duty cycle, 250 amps, 30 volts at 35% duty cycle.
200 Amp DC Diesel Engine Driven Welder
L
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L
N
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L
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C
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CV
1.75
kW
D
Output
Input
Advantage Lincoln
• Pure DC Generator Welding Output
− Produces the welding arc preferred by pipeline operators and
contractors for precise code consistency!
• DC Exciter
− Supplies pure DC current to the welding generator as desired by the
most discriminating operators.
• All Copper Windings
− Enhances arc stability for a really smooth, high performance arc.
• Custom Arc®Dial
− Dial in the right arc, right now! 150 RPM high idle OCV adjustment
for enhanced fine tuning on pipe. (See inside)
• Five Current Ranges with Overlap
− For stick welding and other processes where slope control is
desired. Fine-tuning within each range.
• 200 Amps Output @ 60% Duty Cycle
− Welds up to 7/32" (5.6 mm) low hydrogen electrode.
• Reliable Industrial Diesel Engine
− 4-Cylinder water-cooled Kubota®engine with electronic governor for
precise speed control.
− Standard engine gauges allow you to monitor performance at a
glance.
The Pipeliner®200D, our 200-amp diesel engine driven
welder, continues the long established reputation of Lincoln’s
200 amp pure DC generator welder for the cross-country
pipeline welding industry. This is the diesel version of the
Pipeliner®200G gasoline engine driven product. t is similar
to the older SA-200 and Classic®gasoline engine driven
products manufactured for years, many of which are still
in use today. The Pipeliner®200D continues to use a DC
exciter, as requested by the most discriminating operators.
The Pipeliner®200D runs at a speed slower than the more
common 1800 RPM units, making this industrial product
unique and especially suited to the needs of cross-country
pipeline operators.
Processes
Stick, Flux-Cored(1), Gouging

Pipeliner®200D
[2]
A CLOSER LOOK
PERFORMANCE
Arc Per ormance
• Pure DC generator welding arc is preferred by pipeliners and
contractors for precise code consistency.
• DC exciter for supplying pure DC current to the welding generator as
desired by the most discriminating operators.
• All copper windings enhance arc stability.
• Custom Arc®150 RPM high idle (OCV) adjustment range —
enhanced fine tuning for performance on pipe.
• 200 amps DC @ 60% duty cycle, 104˚F (40˚C). Weld up to 7/32”
(5.6mm) low hydrogen electrode.
• Gouge with up to 5/32" (4.0 mm) carbons.
DC Auxiliary Per ormance
• 1,750 total watts of DC auxiliary power from a single 120V outlet for
grinders and lights. DC power is less likely to bog down a grinder
compared to AC power. (Not for use with AC voltage equipment.)
FEATURES
• Quiet, smooth-running, 4-cylinder, water-cooled Kubota®industrial
diesel engine with electronic governor for precise speed control.
• Noise at 200A/40V rated output: 97.9 dB sound power (Lwa),
73.6 dBA at 23 ft. (7 m)
• Five overlapping current ranges for stick pipe welding and other
processes where slope control is desired. Fine-tuning within each
range provides precise control.
• Gauges indicate oil pressure, engine temperature and battery charg-
ing amps.
• Single-side engine access for easy routine maintenance.
• Oil drain system is standard. Includes ball valve and hose to direct
oil beyond the base of the machine.
• Compact size for installation on truck beds.
• Local/Remote switch and remote receptacle are factory installed to
allow easy connection of the optional remote control.
Stick Welding
• Optional K924-5 Remote Control Kit for stick welding includes
remote box and 100 ft. (30.5m) cable. Make fine current adjust-
ments at the work, not back at the welder.
Wire Welding
• Optional Wire Feed Module for CV-wire welding. Increases produc-
tivity and reduces welding costs. Use LN-25 or LN-15 Across-The-
Arc wire feeders. Built-in contactor for “cold-tip” electrode. (When
CV wire welding with optional Wire Feed Module, idler may need to
be set to “high” position for low current processes.)
• Optional K2464-1 Remote Control Kit for stick and wire welding. For
machines that have the K623-1 Wire Feed Module installed. Make
output adjustments up to 100 ft. from the machine.
1. Current Range Selector
2. Idler Control Switch
3. On/Off Switch
4. Engine Protection Light
5. 120V DC Receptacle
6. Engine Temperature Gauge
7. Battery Charging Ammeter
8. Engine Oil Pressure Gauge
9. Fine Current Adjustment
10. Engine our Meter
11. Start Button
12. Glow Plug Button
13. Local/Remote Control Switch
14. Local/Remote Control Receptacle
15. 15 Amp Fuse for auxiliary receptacle and remote
16. Custom Arc®igh Idle Speed (OCV) Adjustment Dial
1.
2.
3.
4.
5.
6.
7.
9.
10.
11.
12.
14.
13.
8.
15.
16.
Key Controls
Use the igh Idle (OCV) engine speed
adjustment dial to change the heat input to the arc:
• Set the arc in the machine’s “sweet spot”.
• Dial in a softer or more digging arc.
• Reduce root pass internal undercut, especially on X60 and X70 pipe.
• Stack iron faster with low heat and a clear puddle on fill passes.
• Avoid arc breaks. Avoid slag that crowds the arc.
• Control fusion on the cap pass with good puddle size and clarity.
.lincolnelectric.com

Pipeliner®200D
.lincolnelectric.com
[3]
A CLOSER LOOK
QUALITY AND RELIABILITY
• Engine hour meter to track scheduled maintenance.
• Automatic engine shutdown protection for low oil pressure or high
water temperature.
• Electronic engine idler extends engine life and reduces fuel
consumption.
• Attractive and durable pearlescent gray finish paint.
• Manufactured under a quality system certified to ISO 9001
requirements.
• Three-year Lincoln warranty on welder. (Engine is warranted
separately by the manufacturer).
MACHINE SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine Operating Fuel
Model Description Horsepower & Displacement Ignition Capacities Speeds Consumption
Kubota®4 Cylinder 27.8 HP @ 1600 RPM Compression F EL: F LL LOAD 0.9 Gals./Hr
V2403M 4 Cycle gnited 15 Gals (57 Ltrs) 1,600 RPM (200A/28V) 3.4 Ltr/Hr
(Diesel)(3) Water-Cooled 149 cu in
EPA Tier 4i Diesel Engine (2.4 ltrs) OIL: HIGH IDLE 0.5 Gals/Hr
Cast ron Cylinders 8.0 Qts (7.6 Ltrs) 1,450-1,600 RPM (adjustable) 1.7 Ltr/Hr
Block / Crank Case COOLANT: LOW IDLE 0.4 Gals/Hr
9.5 Qts (9.0 Ltrs) 1,400 RPM 1.4 Ltr/Hr
(1) Based on a 10 minute period. High Altitude: For maximum rating, derate the output 4% for every 1,000 ft. (300 m) above 4,900 ft. (1,500 m).
(2) Height is to top of exhaust elbow. Case height is 40.9 in. (1039 mm).
(3) Engine warranty for U.S. and Canada is 2 years/2,000 hours, 3 years major components. Some component limitations exist for Canada. See warranty statement for details.
Product Ordering Rated DC Output(1) DC Current Generator Dimension Weight
Name Information Description Current/Voltage/Duty Cycle Fine Adjustment Range Power H(2) x W x L lbs. (kg)
Pipeliner®200D K6090-11 200 Amp Lincoln “Plus” Rating 40 - 300 Amps 1750 Watts 45.5 x 24.0 x 68.0 in 1311
DC Welder 200A /40V/60% DC Auxiliary Power (1156 x 610 x 1727mm) (595)
220 - Max
All Copper NEMA Rating 160 - 240 15 Amps @
Windings 200A / 28V / 60% 120 - 190 120V DC
80 - 130
Pure DC Power Min - 90
Generator
C U S T O M E R A S S I S T A N C E P O L I C Y
The business of The Lincoln Electric Company®is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of
our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to
inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not
in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume
any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or
implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is
specifically disclaimed.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the
customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

PIPELINER®200D K6090-11
RECOMMENDED GENERAL OPTIONS
Spark Arrestor Kit K903-1
Medium Welder Trailer with Duo- itch™: 2" Ball/Lunette Eye itch K2636-1
- Fender & Light Kit K2639-1
- Cable Rack K2640-1
Service Indicator Kit K1858-1
Stainless Steel Sheet Metal Kit K2423-1
RECOMMENDED STICK OPTIONS
Accessory Kit, 400 amp K704
Accessory Kit, 150 amp K875
Remote Control K924-5
RECOMMENDED WIRE FEEDER OPTIONS
Wire Feed Module K623-1
Remote Control Kit (Stick &Wire) K2464-1
LN-25 PRO Wire Feeder K2613-1
Magnum®350 Innershield®Welding Gun K126-2
Drive Roll and Guide Tube Kit, .068"-.072" (for LN-25 PRO) KP1697-068
Drive Roll and Guide Tube Kit, 5/64" (for LN-25 PRO) KP1697-5/64
TOTAL:
THE LINCOLN ELECTRIC COMPANY®
22801 St. Clair Ave., Cleveland, O 44117-1199 • 216.481.8100 • www.lincolnelectric.com
PIPELINER®200D ORDER FORM
PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE
RECOMMENDED OPTIONS
Accessory Kit
For stick welding. Includes 20 ft. (6.1 m)
#6 electrode cable with lug, 15 ft. (4.6 m)
#6 work cable with lugs, headshield, filter
plate, work clamp, electrode holder and
sample pack of mild steel electrode. 150
amp capacity.
Order K875
Remote Control
Remote control rheostat permits machine
output changes up to 100 ft. (30.5m) from
the machine. Plugs into receptacle on
control panel.
Order K924-5
WIRE FEEDER OPTIONS
Wire Feed Module
Provides constant voltage (CV) output
with improved arc stability for Innershield®
welding. Recommended wire feeder is
LN-25.
Order K623-1
Remote Control Kit (Stick & Wire)
For Classic®& Pipeliner®machines that
have the wire feed module. Contains
a rheostat for stick output, a
potentiometer for wire output and
100 ft. (30.5m) of control cable.
Order K2464-1
LN-25 PRO Wire Feeder
Portable CC/CV unit for flux-cored and
MIG welding with MAXTRAC®wire drive
system. Includes Gas Solenoid & Internal
Contactor. Requires Wire Feed Module.
Order K2613-1
Magnum®350 Innershield®Gun
( or LN-25 PRO)
For self-shielded wire with 15 ft. (4.5m)
cable. For .062"-3/32"
(1.6-2.4 mm) wire.
Order K126-2
Drive Roll and Guide Tube Kit
( or LN-25 PRO,)
For cored or solid steel wire.
Order KP1697-068
for .068"-.072" (1.8 mm)
KP1697-5/64
for 5/64" (2.0 mm)
GENERAL OPTIONS
Spark Arrestor Kit
Attaches to muffler exhust tube. Virtually
eliminates spark emissions.
Order K903-1
Medium Welder Trailer
For heavy-duty road, off-road, plant and
yard use. Includes pivoting jack stand,
safety chains, and 13" wheels. Stiff .120"
welded rectangular steel tube frame
construction is phosphate etched and
powder coat painted for superior rust and
corrosion resistance. Low sway
suspension gives out-standing stability
with manageable tongue weight. Wheel
bearings are packed with high viscosity,
high pressure, low washout Lubriplate®
grease. Includes a Duo- itch™:a 2"
Ball/Lunette Eye combination hitch.
Overall width: 60".
Order:
K2636-1 Trailer
K2639-1 Fender & Light Kit
K2640-1 Cable Rack
Service Indicator Kit
Provides a GO/NO-GO visual indication
of air cleaner element useful service life.
Filter service based on restriction
readings allows the longest life possible
from the filter and best engine protection.
Order K1858-1
Stainless Steel Sheet Metal Kit
Stainless steel roof and doors. Also
includes decals (mounted), door latches,
door hooks, bumpers and all required
mounting hardware. Fits K6090-9 and -10
Pipeliner®200D and K1643-1 thru -10
Classic®300D
Order K2423-1
STICK OPTIONS
Accessory Kit
For stick welding. Includes 35 ft. (10.7 m)
2/0 electrode cable with lug, 30 ft. (9.1 m)
2/0 work cable with lugs, headshield, filter
plate, work clamp and electrode holder.
400 amp capacity.
Order K704