Lincoln Electric PIPELINER IM769 User's Manual
Contents
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3. E 6 TROUBLESHOOTING E 6 ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the Auto Position Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Measure DC Voltage on Replace Idler Idler Solenoid Coil Control Switch 12 VDC 0 VDC Check Continuity of Check for Jamming Current sensor from Idler of the Idler Solenoid PC Board Terminal Mechanism or a broken to Ground Terminal Return Spring Open Closed 1 Check Wiring in Replace Current Idler Solenoid Sensor Circuit 2 Replace Idler P C Board A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PIPELINER 200D LINCOLN 5 E 7 TROUBLESHOOTING E 7 ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position Engine Will Not Pick Up Speed When The Arc is Struck The Auxiliary Power Load is Turned ON Power Load Too Small Try Load Above 150 Watts Engine Does Not Pick Up Speed Current sensor may be defective and not closed To Check Shortthe Lead from current sensor to P C Board to the Welder Frame Engine Picks Up Speed Engine Does Not Pick Up S
4. F 2 Dimension mii F 3 Parts 448 INSTALLATION A TECHNICAL SPECIFICATIONS Pipeliner 200D K6090 9 INPUT DIESEL ENGINE Make Model Description Horsepower Operating Displacement cu in Itrs Starting System Capacities 12VDC Battery 4 Oylinder and starter Fuel 571 4 Stroke High uel 15gal 57L Naturall 1600RPM Oil 8 7 qts Perkins paries 1600RPM Push Button 8 2L 104 22 Water Full Load 135 6 22 Starter 1550RPM Cooled Engine Low Idle 650 Cold Radiator Coolant 1400RPM crank amps 9 5 ats 9 0L RATED OUTPUT 104 F 40C WELDER DESCRIPTION RATED DC OUTPUT DUTY CYCLE DC CURRENT RANGE VOLTS RATED AMPS Fine Adjustment in each Range 200 Amp DC Welder Lincoln Plus Rating 40V 200A All Copper Windings 40 300 Amps Pure DC Power NEMA Rating 28V 200A Generator RATED OUTPUT 104 F 40C GENERATOR Auxiliary Power 1 80 kW 15 Amps 120V DC 9 35 Duty Cycle ENGINE COMPONENTS Full Pressure with Full Flow Filter Indirect Fuel Injector Mechanical Governor Electrical Shutoff Solenoid Mechanical Fuel Pump AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Shutdown on low oil Single Element Automatic Idler Made from long life pressure and engine aluminized steel temperature PHYSICAL
5. m 086 ONILNNON 00 ONILNNOW 05 ADS 95 2 ams os T Cl LE 00 72 0899 PIPELINER 200D LINCOLN NOTES PIPELINER 200D LINCOLN 5 NOTES PIPELINER 200D LINCOLN 5 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR LiH 7 amp nf dchsn zucct MLMPT APSSAPREBS E GUB Oa CRM ER Xe AMI Qi el jad Quali Y O ay slt AL usu DA dax ule Y Jio moe Keep flammable materials away el ma
6. Negative polarity connect the electrode cable to the Negative stud These connections should be checked periodically and tightened if necessary When welding at a considerable distance from the welder be sure you use ample size welding cables RECOMMENDED COPPER CABLE SIZES Cable Sizes for Combined Length of Electrode Plus Work Cable Duty Cycle Up to 200 ft 200 250 ft 60 1 1 0 PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instructions supplied with this machine WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling e Wipe up spilled fuel and allow DIESEL FUEL fumes to clear before starting can engine cause fire Do not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY PIPELINER 200D LINCOLN amp 4 INSTALLATION A 4 OIL ew This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W 30 oil This oil should be acceptable for most typical ambient temperatures Consult the engine operation manual for specific engine manufacturers recommendations Upon receipt of the welder check the engine dipstick to be sure the oil is at the full mark Add if required DO NOT OVERFILL FUEL g Fill the fuel tank with the grade of fuel recommended in the Engine Operators Manual Make sure fuel valve on t
7. and local laws regarding possible additional requirements Choice of 2 hitches and add on fender amp light package Order K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit A WARNING Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric Wire Feed Module K623 1 Provides constant voltage CV output with improved arc stability for Innershield welding Excellent for MIG welding Recommended wire feeders are the LN 7 LN 23P and LN 25 Spark Arrestor Kit K903 1 Includes a heavy gage steel approved spark arrestor clamp and adapter for mounting to the muffler exhaust pipe Oil Drain Kit K1586 1 Includes ball valve hose and clamp PIPELINER 200D LINCOLN 5 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be neces sary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is com plete Always use the greatest care when work ing near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by followi
8. equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operat ed environmental conditions likely maintenance 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specific requirements for use on pub lic highways VEHICLE MOUNTING A WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacture s instructions INSTALLATION A 3 POLARITY CONTROL AND CABLE SIZES With the engine off route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail see size recommendations below For Positive polarity connect the electrode cable to the terminal marked Positive For
9. is on your right side the work cable should also be on your right side AR Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 PIPELINER 200G LINCOLN amp SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semi
10. 0D is equipped with a wet charged battery The charging current is automatically regulat ed when the battery is low after starting the engine to a trickle current when the battery is fully charged When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed The correct polarity is NEGATIVE GROUND PIPELINER 200D LINCOLN amp B 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing eInsulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 23 Use in open well ventilated areas or 4 GA vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or 26 guards off MTM Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Operate the welder with the doors closed Leaving the doors open changes the designed air flow and can cause overheating GENERAL DESCRIPTION The Pipeliner 200D is a heavy duty engine driven DC arc welding power source capable of p
11. ARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp GASES can be dangerous Keep your head out of the fumes e Use ventilation or exhaust to remove fumes from breathing zone 2 2 explosion Keep flammable material away ARC RAYS can burn K 2 Wear eye ear and body protection DUTY CYCLE The NEMA output rating of the Pipeliner 200D is 200 amperes at 280 arc volts on a 60 duty cycle Duty cycle is based on a ten minute period thus the welder can be loaded at rated output for six minutes out of every ten minute period 0 The Lincoln Plus output rating at 60 duty cycle is 200 amperes at 40 Volts CONTROL OF WELDING CURRENT DO NOT TURN THE CURRENT RANGE SELEC TOR WHILE WELDING because the current may arc between the contacts and damage the switch CAUTION The Current Range Selector provides five overlap ping current ranges The Fine Current Adjustment adjusts the current from minimum to maximum within each range Open circuit voltage is also controlled by the Fine Current Adjustment permitting control of the arc characteristics A high open circuit voltage setting provides the soft buttering arc with the best resistance to pop outs preferred for most welding To get this characteristic set the Current Range Selector to the lo
12. DIMENSIONS HEIGHT WEIGHT 40 94 in 1039 9 mm 1318 lbs 598 kg of enclosure add 8 0 203 2mm for exhaust 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced Based on a 10 minute period PIPELINER 200D LINCOLN amp A 2 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill 9 Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 3 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual EXHAUST SPARK ARRESTER Some federal state or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard mufflers inclu
13. Design Summary iii B 1 B 2 Engine Ema B 2 Starting the Perkins 104 22 B 2 Stopping the ENGINE sanirane se a ee dee ee B 2 Typical Fuel CONSUMPTION B 2 Engine Break ri oiii ieee a anes B 3 Welder Operation sise B 3 BACH B 3 Control of Welding Current ss B 3 B 4 Dia dao e B 4 ACCOSSOMIOS Section C Optional Equipment Field Installed C 1 P Section D Safety Precautions iii D 1 General Instr ctions imet cir ccrta Ecce rer eet ies D 1 Cooling SY StS aide ede cared redeas esac D 1 re atia D 1 Bearings octo e D 2 Commutatorand Brushes ette olor e ig e en eei ER eed a oce D 2 Idler Maintenance iii D 2 Nameplates E D 2 Purging Air from Fuel System D 2 D 3 Engine Service us iio dee ed eect deceit D 3 Troubleshooting eaor Section E Safety 1 How to Use Troubleshooting Guide E 1 Troubleshooting 3 E 2 thru 7 5 Rene RER Section F Laure rase eh meule ire nine F 1 Remote Control Wiring Connection
14. IM769 PIPELINER 200D Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10929 OPERATOR S MANUAL LE rli y n e e OOGQ Q NN E _ S Te 202002 Lincoln Global mo World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com i SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THE
15. INS 104 22 DIESEL ENGINE 1 Turn the IDLER switch to HIGH 2 Turn the IGNITION switch to ON Press the Glow Plug button for 20 to 30 seconds maximum 60 seconds 4 Press the Start button When the engine starts run ning release both buttons If the engine fails to start in 20 seconds wait 30 seconds and repeat the above procedure Observe the oil pressure If no pressure shows within 30 seconds stop the engine and consult the engine operating manual To stop the engine turn the IGNITION switch to OFF If the engine protection warning light comes on dur ing cranking or after start up the IGNITION switch must be turned OFF to reset the engine protection system 7 Allow the engine to run at high idle speed for sever al minutes to warm the engine Stop the engine and recheck the oil level after allowing sufficient time for the oil drain into the pan If the level is down fill it to the full mark again The engine controls were prop erly set at the factory and should require no adjust ing when received OPERATION B 2 COLD WEATHER STARTING With a fully charged battery and a proper weight oil the engine should start satisfactorily even down to about 15 F 26 C If the engine must be frequently started at or below 15 F 26 C it may be desirable to install cold starting aides Note Extreme cold weather starting may require long
16. IR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 gt MAGNETIC FIELDS be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current fl
17. SSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les TRANSFORMATEUR ET Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 PIPELINER 200G LINCOLN 5 V V for selecting QUALITY product by Lincoln Electric We want
18. automatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 0 Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to
19. ce Facility for technical troubleshooting assistance before you proceed PIPELINER 200D LINCOLN TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS COURSE OF ACTION White or Blue Smoke Dark Grey Smoke Faulty Charging Starter Motor does not run Engine Protection Light not coming on after the ignition switch has been in the on position for more than 60 seconds with the engine not started Excess engine oil Too low viscosity of the engine oil Faulty injection timing Unsuitable fuel Excess injection Faulty function of the engine Overloading Clogged air cleaner If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Loose fan belt Faulty wiring Faulty battery Worn out alternator brush Loose or damaged wiring Dropped voltage of the battery Damaged starter motor including solenoid Broken Light Bulb Faulty light wiring to GND or P C Board Faulty Idler Engine Protection P C Board A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PIPELINER 200D LINCOLN
20. circuit due to loose or broken wire Electrode lead or work lead con nection may be poor Wrong grade of brushes may have been installed on generator Field rheostat may be making poor contact and overheating Generator or exciter brushes may If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility be loose or missing exciter may be open Exciter may have lost excitation Series field and armature circuit may be open circuited Current setting may be too high Polarity may be wrong CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PIPELINER 200D LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throug out this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS COURSE OF ACTION PROBLEMS Welding current too great or too 1 Exciter output low causing low small compared to indication on the output compared to dial indica dial tion If all recommended possible areas Operating speed too low or high of misadjustment have been checked and the problem persists Contact your local Lincoln Arc continuously pops out Current Range Selecto
21. ded with these welders do not qualify as spark arresters When required by local ulations suitable spark arrester must be installed and properly maintained CAUTION Use of an incorrect arrester may lead to engine dam age or performance loss Contact the engine manu facturer for specific recommendations LOCATION VENTILATION Always operate the welder with the doors closed Leaving the doors open changes the designed air flow and may cause overheating The welder should be located to provide an unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an outside area INSTALLATION A 2 CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150mm beyond the equipment on all side MACHINE GROUNDING According to the United States National Electrical Code the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle Some state local or other codes or unusual operating circumstances may require the machine frame to be grounded It is recommended that you determine the extent to which such requirements may apply to your particular sit
22. er glow plug operation WARNING Under NO conditions should ether or other start ing fluids be used STOPPING the ENGINE 1 Turn the IGNITION switch to OFF At the end of each day s welding check the crankcase oil level drain accumulated dirt and water from the sediment bowl under the fuel tank and refill the fuel tank to minimize moisture condensation in the tank Also running out of fuel tends to draw dirt into the fuel system When hauling the welder between job sites close the fuel feed valve beneath the fuel tank If the fuel supply is cut off or runs out while the fuel pump is operating air may be entrapped in the fuel distribution system If this happens bleeding of the fuel system may be necessary Use qualified person nel to do this per the instructions in the MAINTE NANCE section of this manual PIPELINER 200D WITH PERKINS 104 22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA Low idle 1400 RPM 33gal hr 1 25ltrs hr No Load High idle 1800 Rpm No load 200 Amps 28 Volts 200 Amps 40 Volts 39gal hr 1 48ltrs hr 67gal hr 2 54ltrs hr 75gal hr 2 84ltrs hr Auxiliary Power 15 Amps 120 Volts 50gal hr 1 89ltrs hr PIPELINER 200D LINCOLN 5 B 3 ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil consumption during initial
23. ficient charging or complete discharge of the battery 3 Lack of fuel 4 Air mixed in the fuel system 5 Clogged fuel filter 6 Irregular and faulty fuel supply Injector pump trouble 7 Glow plug not heated 8 Improper viscosity of the lubricat ing oil If all recommended possible areas 9 Clogged air cleaner of misadjustment have been 10 No compression checked and the problem persists 11 Engine protection light is on Contact your local Lincoln 12 Defective governor Authorized Field Service Facility 13 Engine defective Engine stops during operation and 1 Lack of fuel the Engine Protection light does not 2 Clogged fuel filter turn on 3 Air mixed in the fuel system 4 Faulty function of the engine Engine stops during operation and 1 Overheating of the engine the Engine Protection light does Lack of coolant turn on Loose or damaged fan belt Clogged radiator Dust or scale clogged in the cool ing water passages Faulty thermostat Lack of oil Overloading e Faulty Idler Engine Protection P C Board 2 Loss of engine oil pressure Lack of engine oil Faulty oil pressure switch Oil leakage from the lubricating system Clogged oil filter Too low viscosity of the engine oil e Faulty Idler Engine Protection P C Board A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Servi
24. he sediment bowl and water separator are in the open position COOLING SYSTEM The radiator has been filled at the factory with a 50 50 mixture of ethylene glycol antifreeze and water Check the radiator level and add a 50 50 solution as needed See engine manual or antifreeze container for alternate antifreeze recommendations BATTERY CHARGING WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away BATTERY ACID can burn eyes and skin lt gt Wear gloves and eye protection and be careful when boosting charging or working near battery To prevent EXPLOSION when a Installing a new battery disconnect the nega tive cable from the old battery first and con nect the negative cable to the new battery last b Connecting a battery charger remove the bat tery from the welder by disconnecting the neg ative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last c Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base To prevent ELECTRICAL DAMAGE when a Installing a new battery b Using a booster Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not running To prevent BATTERY BUCKLING tighten nuts on battery clamp until snug The Pipeliner 20
25. int Tighten the vent screw 8 Contact your Perkins Engine repair facility if prob lems persist FIGURE D 1 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE 20 50 HOURS EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE NOTE 2 MAINTENANCE ITEM TYPE OR QUANTITY Coolant level Concentration of antifreeze 50 50 Water Ethylene Glycol Coolant NOTE 3 9 5qrts 9 0L Engine oil level NOTE 1 Engine oil NOTE 1 amp 3 8 7qrts 8 2L including filter Engine oil filter Perkins 140517000 Drain water separator amp fuel strainer Fuel filter canister Perkins 26560017 Tension of alternator drive belt Alternator drive belt wear Alternator drive belt Perkins 080109080 Air filter earlier check may be req d Air filter element Donaldson P 181050 Nelson 70206N Check and adjust idle speed Tighten cylinder head Valve clearances Intake 008 exhaust 008 Electrical systems All nuts and bolts for tightness Injector performance Contact Perkins Leaks or engine damage Battery Inspect C Clean R Replace Notes 1 Consult Engine Operators Manual for oil recommendations 2 Consult Engine Operators Manual for additional maintenance schedule information 3 Fill slowly Ensure correct quantity is used o Q Above operations to be carried out by trained personnel
26. lists the obvious external possibilities that may contribute to the machine symptom ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing MY e Keep away from moving parts Remove guards only when necessary and replace when work requiring removal is complete Only qualified personnel should install use or service this equipment A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PIPELINER 200D LINCOLN TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throug out this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS COURSE OF ACTION Machine fails to hold the heat con stantly Welder starts but fails to generate current Welding arc is loud and spatters excessively Exciter may not be operating Field circuit of generator or PROBLEMS Rough or dirty commutator Brushes may be worn down to limit Field circuit may have variable resistance connection or intermit tent open
27. n the idler oper ates as follows When welding or drawing power for lights or tools approximately 100 150 watts minimum from the receptacle the idler solenoid activates and the engine operates at high idle speed e When welding ceases or the power load is turned off a preset time delay of about 15 seconds starts This time delay cannot be adjusted If the welding or power load is not re started before the end of the time delay the idler solenoid deacti vates and reduces the engine to low idle speed AUXILIARY POWER 1 80 kW of 120V DC auxiliary power at 35 duty cycle maximum is available at the receptacle located on the control panel PIPELINER 200D LINCOLN 5 1 ACCESSORIES C 1 OPTIONAL FEATURES Field Installed Accessory Set K704 Includes electrode and work cables headshield work clamp and electrode holder Remote Control Kit K924 5 Contains a remote control rheostat and 100 ft 30 5m cable for adjusting the OCV at the welding site Remote Control Kit K2464 1 Contains a remote control rheostat for adjusting CC STICK OCV remote control potentiometer for adjusting CV STICK OCV and 100ft 30 5m cable See Wiring Connection Diagram Section Trailer K957 1 Two wheeled trailer for in plant and yard towing at speeds under 20 mph only Trailer K953 1 Two wheeled trailer with optional fender and light package For highway use consult applicable federal state
28. nd any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 PIPELINER 200G LINCOLN SAFETY PR CAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuit
29. ng Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode Ea if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they be struck or subjected to physical damage safe distance from arc welding or cutting operations a
30. ng the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill S Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual GENERAL INSTRUCTIONS 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation 2 Current Range Selector contacts should not be greased To keep the contacts clean rotate the current control through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld 3 Put a drop of oil on the Current Range Selector shaft at least once every month 4 When necessary remove the sediment bowl from beneath the gas tank and clean out any accumulat ed dirt and water Replace the fuel filter in the fuel line as needed 5 See the engine manufacturers operation manual for detailed engine maintenance and troubleshoot ing ins
31. operation excessive oil use wetstacking oil or tar like sub stance at the exhaust port or excessive smoke is not normal Larger machines with a capacity of 350 amperes and higher which are operated at low or no load condi tions for extended periods of time are especially sus ceptible to the conditions described above To accomplish successful engine break in most diesel powered equipment needs only to be run at a reason ably heavy load within the rating of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resistive load bank Note that any attempt to short the output studs by connecting the welding leads together direct shorting of the output studs or connecting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty 2 Set the welder controls for an output current and voltage within the welder rating and duty cycle Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level OPERATION B 3 WELDER OPERATION A W
32. ore attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Installation Section A Technical NN Me ee A 1 Safety Precautions ss A 2 pi 2 Location Ventilation sis A 2 Machine Grounding BP te eed A 2 ELITS A 2 MCI A 3 Polarity Control and Cable Sizes A 3 Pre Operallom Service oic Mater Ne CL DACH a ERE due A 3 uM ILI A 4 ab A 4 Cooling SY Ste E 4 LEER 4 er mec Section B Safety Precautions issue B 1 General eel MIN B 1
33. owing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety MS aM minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work cables If the electrode cable
34. peed 1 Check Idler Circuit Wiring and Repair as 1 Check Continuity of Idler Required Solenoid Coil 8 5 9 0 ohms and Replace as 2 Replace Current Sensor Required 2 Check for Jamming of the Idler Solenoid Mechanism 3 Check Idler Circuit Wiring and Repair as Required 4 Replace Idler P C Board NOTE If the engine will not idle up or down under both weld and auxiliary load check idler circuit wiring The direction of leads entering the current sensor may be incorrect A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed PIPELINER 200D LINCOLN 5 Jequunu epoo jueuudinbe y e 104 ueuiyedeq 20S eui si WeiBelp J sjaued y JO euo uo y episul peised si epoo e 0 siy Aq Je 104 ayeunooe eq jou Aew 51 SIUL LON 90021 LL SNOILO3NNOO 3S3H L NIMYN ONINNNE 34 LON LSAW ANIHOVW ATAWASSV LVLSOWYSHL dV 092 QV31AAV3H H313WOLLN31Od IOH1INOO 310W3H HSN SAN OL 1O3NNOO SHOISIS3H T3NVd FINGOW
35. practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 PIPELINER 200G LINCOLN 5 SAFETY 7 WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Weldi
36. ptacle for auxiliary power Welding Generator The Pipeliner 200D uses the old style round all cop per FJW Generator frame which provides the cus tomer with the original Classic pipe welding arc Engine Idler The Pipeliner 200D is equipped with an electronic automatic engine idler It automatically increases and decreases engine speed when starting and stopping welding or using auxiliary power A built in time delay permits changing electrodes before the engine slows to its low idle speed The Idler control switch on the panel locks the idler in the full speed position when desired Auxiliary Power 1 80 kw of nominal 120V DC auxiliary power at 3596 duty cycle maximum Output voltage is maintained within 1096 at all loads up to rated capacity Welder Enclosure The complete welder is rubber mounted on a rugged steel C channel base The output terminals are placed at the side of the machine so that they are protected by the door The output terminals are labeled and PIPELINER 200D LINCOLN 5 B 2 Cranking System 12V electric starter is standard Air Cleaner Heavy duty two stage dry type Exhaust A muffler and stainless steel exhaust outlet pipe are standard Engine Hour Meter A meter to record the hours of operation ENGINE OPERATION Operate the welder with the doors closed Leaving the doors open changes the designed air flow and can cause overheating STARTING THE PIPELINER 200D PERK
37. r switch Authorized Field Service Facility may be set at an intermediate position Flashing the exciter field consists of passing current through the fields using an external source of 6 to 125 volts of DC power from a storage battery or DC generator If using a DC generator keep the generator turned off except when actually applying the flashing current To flash the fields 1 Turn the welder off Raise one exciter brush off the commutator 2 On Lincoln welders attach the positive lead from the external DC source to the right hand brushholder 3 Carefully holding an insulated section of the negative lead from the DC source touch its lug or clamp to the left hand brushholder for five seconds Pull it away quickly to minimize arcing Remove the lead from the right hand brushholder replace the brush on the commutator start the welder and the generator voltage should build up A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed JULY97 PIPELINER 200D LINCOLN 5 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS COURSE OF ACTION Engine does not start or operates 1 Faulty Ignition switch and or Irregularly Injector pump solenoid 2 Insuf
38. rcuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRE
39. reathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU CARE 24758 else sis PARAH 37 amp Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas XL7TTL2A 9 AVCWRUD PSB RET BRAY FE HMDS RK AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschu
40. roviding DC constant current output for stick welding and DC TIG welding With the addition of the optional Wire Feed Module the Pipeliner 200D will provide constant volt age output for running the LN 25 wire feeder The optional Remote Control Kit provides a remote control rheostat for remote fine current and open cir cuit voltage adjustment The Pipeliner 200D has Diesel Engine Protection In the event of sudden low oil pressure or high coolant temperature the engine immediately shuts down The Pipeliner 200D has a current range of 40 300 DC amps with output ratings as follows RATED OUTPUT DUTY CYCLE 200A 28V 60 200A 40V 60 The unit is also capable of providing 1 80 kw of 120V DC auxiliary power at 35 duty cycle maximum This unit uses the PERKINS 104 22 Industrial water cooled diesel engine DESIGN SUMMARY Control Panel Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine The welder controls consist of a five step Current Range Selector switch and a Fine Current Adjustment rheostat The welder is equipped with a Start button Glow Plug button Ignition switch Idler control switch hour meter Engine Protection indicator light Remote Local Switch and Receptacle a battery charging ammeter an oil pressure gauge and engine coolant temperature gauge The control panel also contains a three prong ground ing type rece
41. s l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court ci
42. ted when the welder is shipped They require no particular attention DO NOT SHIFT THE BRUSHES or adjust the rocker setting Shifting of the brushes may result in Change in machine output e Commutator damage e Excessive brush wear Periodically inspect the commutator and brushes by removing the covers DO NOT remove or replace these covers while the machine is running Commutators require little attention However if they are black or appear uneven have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone Never use emery cloth or paper for this purpose Replace brushes when they wear within 1 4 of the pigtail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experienced mainte nance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes After stoning blow out the dust with low pressure air Arcing or excessive exciter brush wear indicates a possible misaligned shaft Have an authorized Field Service Shop check and realign the shaft IDLER MAINTENANCE A CAUTION Before doing electrical work on the idler printed circuit board disconnect the battery When installing a new battery or using a jumper bat tery to start the engine be sure the battery polarity is connected properly The correct polarity is negati
43. terial combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM EA e i8 9 MR IF eis Jo ALD al gll pis e Ac AI uie Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo A HAUSHERMRELTTF EU RRR HRSESOREME ez 119 59 A de vues al gl ne 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from b
44. the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety
45. tructions COOLING SYSTEM The Pipeliner 200D is equipped with a pressure radia tor Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodi cally to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type ENGINE MAINTENANCE Refer to the Engine s operation and mainte nance manual for additional information on the engine PIPELINER 200D LINCOLN D 2 MAINTENANCE D 2 BEARINGS This welder is equipped with a double shielded ball bearing having sufficient grease to last indefinitely under normal service Where the welder is used con stantly or in excessively dirty locations it may be nec essary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease COMMUTATOR AND BRUSHES A WARNING Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be thrown out by the rotat ing armature when stoning the commutator The generator brushes are properly adjus
46. tzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE CHRRIARRARS SHAE Ro e 20 Sel AE Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai dul jua Sarin e Qui BALL cal sd ue Aie Ab pha J gail e cuts gall l Jai y e ue Cut Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA CUCRITEOSSXSUEIL HS SUCR Rr de OE AS EL ES AMENER 0 HYRAS SAAD HA HHR ele BEHE ET gl illai Qui al ply 3 Gail guet LINCOLN 5 World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
47. uation and follow them explicitly A machine grounding stud marked with the symbol is provided on the welding generator frame foot In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat ed joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment LIFT BAIL A lift bail is provided for lifting with a hoist A WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail FALLING EQUIPMENT can cause injury PIPELINER 200D LINCOLN A 3 TRAILERS See ACCESSORIES SECTION If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding
48. ve ground Damage to the engine alternator and the printed circuit board can result from incorrect connec tion 1 The solenoid plunger must work freely and not bind Dust the plunger about once a year with graphite powder 2 Proper operation of the idler requires good ground ing of the printed circuit board current sensor and battery 3 Idler solenoid is activated for high idle 4 If desired the welder can be used without automat ic idling by setting the Idler switch to the High position NAMEPLATES Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replace ment item number PURGING AIR from FUEL SYSTEM Perkins 104 22 Engine Keep fuel clear of open flames or arcs allow engine to cool before working on the fuel system Wipe up any spilled fuel and do not start engine until fumes clear If the engine is running rough and you suspect air has been trapped in the fuel system EG the engine was allowed to run out of fuel perform the following steps using qualified personnel PIPELINER 200D LINCOLN D 3 MAINTENANCE D 3 1 Loosen by two or three turns the vent screw 2 Operate the electric fuel pump by turning the Figure D 1 on the fuel inlet connection Ignition switch ON until fuel free of air flows l from the vent po
49. west setting that still provides the current you need and set the Fine Current Adjustment near maximum For exam ple to obtain 175 amps and a soft arc set the Current Range Selector to the 190 120 position and then adjust the Fine Current Adjustment for 175 amps PIPELINER 200D LINCOLN P B 4 OPERATION When a forceful digging arc is required usually for vertical and overhead welding use a higher Current Range Selector setting and lower open circuit volt age For example to obtain 175 amps and a forceful arc set the Current Range Selector to the 240 160 position and the Fine Current Adjustment setting to get 175 amps CAUTION DO NOT attempt to set the Current Range Selector between the five points designated on the nameplate These switches have a spring loaded cam which almost eliminates the possibility of setting this switch between the designated points IDLER OPERATION Start the engine with the Idler switch in the High position Allow it to run at high idle speed for several minutes to warm the engine See Specifications for operating speeds The idler is controlled by the Idler toggle switch on the welder control panel The switch has two posi tions as follows 1 In the High Le position the idler solenoid acti vates and the engine goes to high idle speed The speed is controlled by the governor 2 In the Auto C positio
50. with reference to the workshop manual where necessary These preventive maintenance periods apply to average conditions of operation If necessary use shorter periods 525557 PIPELINER 200D LINCOLN 1 TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE
51. you Thank You io take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely bef
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