RETURN TO MAIN MENU PIPELINER 200D IM769 October, 2004 For use with machines having Code Numbers 10929 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 thoughtful 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii SAFETY WELDING SPARKS can 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. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• 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.
vi vi TABLE OF CONTENTS Page Installation .........................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.................................................................................................A-2 Exhaust Spark Arrester..........................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Pipeliner 200D (K6090-9) INPUT - DIESEL ENGINE Make/Model Description Horsepower Operating Displacement cu. in.(ltrs) SPEED Perkins 104.22 4 Cylinder 4 Stroke Naturally Aspirated Water Cooled Engine Starting System 12VDC Battery and starter High 28.2 HP 1600RPM @ 1600RPM Full Load 1550RPM Push Button Starter 135.6 (2.2) (650 Cold crank amps) Low Idle 1400RPM Capacities Fuel: 15gal.(57L) Oil: 8.7 qts. (8.2L) Radiator Coolant 9.5 qts. (9.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS CAUTION 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.
A-3 A-3 INSTALLATION TRAILERS (See ACCESSORIES SECTION) POLARITY CONTROL AND CABLE SIZES 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: 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.
A-4 A-4 INSTALLATION OIL BATTERY CHARGING WARNING 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. GASES FROM BATTERY can explode.
B-1 B-1 OPERATION The Pipeliner 200D has a current range of 40-300 DC amps with output ratings as follows: 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.
B-2 B-2 OPERATION Cranking System A 12V electric starter is standard. COLD WEATHER STARTING Air Cleaner Heavy duty two-stage dry type Exhaust A muffler and stainless steel exhaust outlet pipe are standard. 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.
B-3 B-3 OPERATION WELDER OPERATION ENGINE BREAK-IN WARNING Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wetstacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal.
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 voltage. 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.
C-1 ACCESSORIES 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.
D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety 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. Do not put your hands near the engine cooling blower fan.
D-2 D-2 MAINTENANCE BEARINGS IDLER MAINTENANCE This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal service. Where the welder is used constantly or in excessively dirty locations, it may be necessary 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.
D-3 D-3 MAINTENANCE 1. Loosen by two or three turns, the vent screw (Figure D.1) on the fuel inlet connection. 2. Operate the electric fuel pump by turning the “Ignition” switch “ON” until fuel, free of air, flows from the vent point. Tighten the vent screw. 3. Contact your Perkins Engine repair facility if problems persist. Vent Screw FIGURE D.
E-1 TROUBLESHOOTING E-1 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throug out this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED COURSE OF ACTION PROBLEMS Machine fails to hold the heat constantly. 1. Rough or dirty commutator. 2. Brushes may be worn down to limit. 3. Field circuit may have variable resistance connection or intermittent open circuit due to loose, or broken wire. 4. Electrode lead or work lead connection may be poor. 5.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throug out this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS RECOMMENDED 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 indicadial. tion. 2. Operating speed too low or high. Arc continuously pops out. 1. “Current Range Selector” switch may be set at an intermediate position.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine does not start or operates Irregularly POSSIBLE AREAS OF MISADJUSTMENTS 1. Faulty Ignition switch and or Injector pump solenoid 2. Insufficient 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 lubricating oil 9.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS White or Blue Smoke 1. Excess engine oil 2. Too low viscosity of the engine oil 3. Faulty injection timing Dark Grey Smoke 1. Unsuitable fuel 2. Excess injection 3. Faulty function of the engine 4. Overloading 5. Clogged air cleaner Faulty Charging 1. Loose fan belt 2. Faulty wiring 3. Faulty battery 4. Worn out alternator brush Starter Motor does not run 1.
E-6 E-6 TROUBLESHOOTING 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 Idler Solenoid Coil Replace Idler Control Switch 12 VDC 0 VDC Check Continuity of Current sensor from Idler PC Board Terminal to Ground Terminal Chec
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 Auxiliary Power Load is Turned ON The Arc is Struck 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: Short the Lead from current sensor to P.C. Board to the Welder Frame. Engine Picks Up Speed 1. Check Idler Circuit Wiring and Repair as Required. 2.
+- 60 B S PIPELINER 200D 58A + - I 200 OIL PRESSURE GAUGE + EXC 212B ALTERNATOR I G B W REMOTE CONTROL POTENTIOMETER BOX CONNECT TO CASE X PLUG FOR REMOTE CONTROL POTENTIOMETER F1 15A 761 SERIES + 820 GND-T RECEPTACLE INLINE CONNECTORS CONNECT TO NEG. BRUSH HOLDER SELECTOR SWITCH SERIES 609 #2 HEAVY LEAD #8 LEAD N WIRE FEED MODULE U + INTERPOLE + - SHUNT B M20056 MUST NOT BE RUNNING * MACHINE WHEN MAKING THESE CONNECTIONS.
F-2 F-2 DIAGRAMS K2 K2464-1 REMOTE REMOT CONTROL CONT W WIRING NG / CONNECTION CONNECT N DIAGRAM DI X Y G B W CV ""WIRE" CONT CONTROL POT CCW RESISTORS CC ""STICK CK CONTROL CONT BLUE RED ORANGE CABLE BLE CONNECTION ION TABLE BLE REMOTE C CONTROL ROL B BOX R CONNECT T TO CA CASE PIN E F G C D LEAD COLOR RED ORANGE BLUE E JUM JUMPER WHITE E JUMPER JUM WHITE THE LINCOLN ELECTRIC COMPANY World’s orld’s Leader Le er in Welding W and an Cutting Cu Products Prod Sales an and Service Service throug
PIPELINER 200D 4.00 41.66 23.00 57.70 N.B. N.A. NOTES: N.A. CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT NO FUEL. N.B. Ø.56 TRAILER MOUNTING HOLES. 3.25 MOUNTING HOLE O.56 SKID 12.25 27.50 66.50 4.00 8.25 O.56 SKID MOUNTING HOLE 37.12 45.50 20.62 18.50 24.00 S10766-11 B 40.
NOTES PIPELINER 200D
NOTES PIPELINER 200D
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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