Lincoln Electric PIPELINER IM769 manual

OPERA TOR’S MANUAL 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 CONT[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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 Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

iv SAFETY iv Mar. ‘ 93 PIPELINER 200G PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre l[...]

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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation .........................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.........................................................[...]

DC CURRENT RANGE Fine Adjustment in each Range 40-300 Amps DUTY CYCLE* 60% RATED DC OUTPUT VOLTS @ RATED AMPS Lincoln Plus Rating 40V @ 200A NEMA Rating 28V @ 200A A-1 INST ALLA TION PIPELINER 200D A-1 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. Wh[...]

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 kil[...]

A-3 INST ALLA TION PIPELINER 200D 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 [...]

A-4 INST ALLA TION PIPELINER 200D A-4 OIL 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[...]

B-1 OPERA TION B-1 SAFETY PRECAUTIONS 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. ---------------------------------------------------------[...]

B-2 OPERA TION B-2 PIPELINER 200D Cranking System A 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 OPERA TION Operate the welder with the doors closed. Leaving the doors open changes[...]

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 operation, excessive oil use, wetstacking (oil or tar like sub- stance at the exhaust port), or excessive smoke is not normal. Larger [...]

B-4 OPERA TION B-4 PIPELINER 200D 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 Curren[...]

C-1 ACCESSORIES C-1 PIPELINER 200D OPTIONAL FEA TURES (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[...]

D-1 MAINTENANCE D-1 PIPELINER 200D SAFETY PRECAUTIONS 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[...]

D-2 MAINTENANCE D-2 PIPELINER 200D 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 l[...]

D-3 MAINTENANCE D-3 PIPELINER 200D I EVERY 400 HOURS OR 12 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 100 HOURS OR 3 MONTHS FIRST SERVICE-(20 / 50 HOURS) EVERY DAY OR EVERY 8 HOURS Perkins #140517000 If necessary use shorter periods. These preventive maintenance periods apply to average conditions of operation. Perkins #26560017 TYPE OR QUANTITY Abov[...]

E-1 TROUBLESHOOTING E-1 PIPELINER 200D 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. CAUTION ELECTRIC SHOCK can kill. • Do not touch electrically live parts such[...]

E-2 TROUBLESHOOTING E-2 PIPELINER 200D Observe all Safety Guidelines detailed throug out this manual 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. CAUTION PROBLEMS[...]

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 t[...]

E-4 TROUBLESHOOTING E-4 PIPELINER 200D Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS[...]

E-5 TROUBLESHOOTING E-5 PIPELINER 200D Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS[...]

E-6 TROUBLESHOOTING E-6 PIPELINER 200D 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[...]

E-7 TROUBLESHOOTING E-7 PIPELINER 200D 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 Power Load Too Small Try Load Above 150 Watts Engine Does Not Pick Up Speed Engine Picks Up Speed 1. Check Idler Circuit Wiring and Repair as Required[...]

F-1 DIAGRAMS F-1 PIPELINER 200D 761 F1 15A 840 B PIPEL INER 2 00D WI RING DI AGRAM M20056 START + 52 + - - 51 56 EXC + PUMP SOLENOID 50 50B S B + R 1 2 3 4 12 3 4 5 6 7 8 9 10 J1 J2 61 60A 58A 51A 53B 57 56A 54B 54 59 58 50A FUEL PUMP 53 GLOW PLUGS 60C 212A 70 GND-B GND- M 212B GND-N S G I S G I AMMETER 200 54D 51G G WK 58H W G GROUND SCREW NEAR EN[...]

F-2 DIAGRAMS F-2 PIPELINER 200D Sales an Sales an d Serv Serv ice throug ice throug h Su h Su bsidiaries bsidiaries a a nd Distribu Distribu tors tors W W orldwide Cleveland , Ohio 4 , Ohio 4 4117-1199 U U .S.A. R TH E LIN COLN ELECTRIC COM PANY W orld’s orld ’s Le Le ad er in W er in W elding an an d Cu Cu tting Prod Prod ucts S 26 0 9 7 A. A [...]

F-3 DIMENSION PRINT F-3 PIPELINER 200D S10766- 11 B 24.00 37.12 66.50 27.50 12.25 4.00 4. 00 23.00 8.25 41.66 3.25 57.70 O .56 SKID MOUNTI NG HOLE O .5 6 SKID MOUNTI NG HOLE N.B. N.B. N.A. NOTES: N.A. CENTER OF GR AVITY WITH OIL AN D WATER IN ENGIN E, BUT NO FUEL. N.B. Ø.56 TRAILE R MOUNTING HOL ES. 20.62 18.50 40.94 45.50[...]

NOTES PIPELINER 200D[...]

NOTES PIPELINER 200D[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

• 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 • World's Leader in Welding and Cutting Products •[...]