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PIPELINER 200D
IM769
October, 2004
PIPELINER 200D
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 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 ca
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi vi TABLE OF CONTENTS Page Installation .........................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.................................................................................................A-2 Exhaust Spark Arrester.....................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Pipeliner 200D (K6090-9) INPUT - DIESEL ENGINE Make/Model Description Horsepower Operating Displacement cu. in.(ltrs) Starting Capacities SPEED System 12VDC Battery 4 Cylinder and starter Fuel: 15gal.(57L) High 4 Stroke 28.2 HP Oil: 8.7 qts. Naturally 1600RPM Perkins @ 1600RPM (8.2L) Push Button Aspirated 104.22 Full Load 135.6 (2.2) Starter Water 1550RPM Cooled Radiator Coolant (650 Cold Engine Low Idle 9.5 qts. crank amps) 1400RPM (9.0L)
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR- WARNING FACES. Do not attempt to use this equipment until you Where there is a combustible surface directly under have thoroughly read the engine manufacturer’s stationary or fixed electrical equipment, the surface manual supplied with your welder. It includes important safety precautions, detailed engine shall be covered with a steel plate at least starting, operating and maintenance instructions, .06”(1.6mm)
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A-3 A-3 INSTALLATION TRAILERS (See ACCESSORIES SECTION) POLARITY CONTROL AND CABLE SIZES If the user adapts a non-Lincoln trailer, he must With the engine off, route the electrode and work assume responsibility that the method of attachment cables through the strain relief bracket on the base and usage does not result in a safety hazard, nor and connect to the studs located below the fuel tank damage the welding equipment. Some of the factors mounting rail. (see size recommendations below).
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A-4 A-4 INSTALLATION OIL BATTERY CHARGING This unit is supplied from the factory with the engine WARNING crankcase filled with a high quality SAE 10W/30 oil. GASES FROM BATTERY can explode. This oil should be acceptable for most typical ambient � Keep sparks, flame and cigarettes temperatures. Consult the engine operation manual away. 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 requi
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B-1 B-1 OPERATION The Pipeliner 200D has a current range of 40-300 DC SAFETY PRECAUTIONS amps with output ratings as follows: WARNING RATED OUTPUT DUTY CYCLE Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s 200A @ 28V 60% manual supplied with your welder. It includes 200A @ 40V 60% important safety precautions, detailed engine starting, operating and maintenance instructions, The unit is also capable of providing 1.80 kw of 120V and parts lists. ----
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B-2 B-2 OPERATION Cranking System COLD WEATHER STARTING A 12V electric starter is standard. With a fully charged battery and a proper weight oil, the engine should start satisfactorily even down to Air Cleaner about -15°F -(26°C). If the engine must be frequently Heavy duty two-stage dry type started at or below -15°F -(26°C), it may be desirable to install cold-starting aides. Exhaust Note: Extreme cold weather starting may require A muffler and stainless steel exhaust outlet pipe are longer g
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B-3 B-3 OPERATION WELDER OPERATION ENGINE BREAK-IN WARNING Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we ELECTRIC SHOCK can kill. offer. While it is normal to see a small amount of � Do not touch electrically live parts or crankcase oil consumption during initial operation, electrode with skin or wet clothing. excessive oil use, wetstacking (oil or tar like sub- � Insulate yourself from work and ground. stance at the exhaust port),
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B-4 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. -----------------------------------
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C-1 C-1 ACCESSORIES OPTIONAL FEATURES (Field Installed) Wire Feed Module (K623-1) - Provides constant voltage (CV) output with improved arc stability for Accessory Set (K704) - Includes electrode and work Innershield welding. Excellent for MIG welding. cables, headshield, work clamp and electrode holder. Recommended wire feeders are the LN-7, LN-23P and LN-25. Remote Control Kit (K924-5) - Contains a remote control rheostat and 100 ft (30.5m) cable for adjusting Spark Arrestor Kit (K903-1) - In
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D-1 D-1 MAINTENANCE 4. When necessary, remove the sediment bowl from SAFETY PRECAUTIONS beneath the gas tank and clean out any accumulat- ed dirt and water. Replace the fuel filter in the fuel WARNING line as needed. Have qualified personnel do the maintenance work. Turn the engine off before working inside 5. See the engine manufacturers operation manual the machine. In some cases, it may be neces- for detailed engine maintenance and troubleshoot- sary to remove safety guards to perform ing
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D-2 D-2 MAINTENANCE BEARINGS IDLER MAINTENANCE CAUTION This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely Before doing electrical work on the idler printed under normal service. Where the welder is used con- circuit board, disconnect the battery. stantly or in excessively dirty locations, it may be nec- ------------------------------------------------------------------------ essary to add one-half ounce of grease per year. A When installing
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D-3 D-3 MAINTENANCE 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 from the vent point. Tighten the vent screw. 3. Contact your Perkins Engine repair facility if prob- lems persist. Vent Screw FIGURE D.1 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
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E-1 E-1 TROUBLESHOOTING 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. _______________________________________________________________
