Lincoln Electric PIPELINER 200G Operator'S Manual Download Page 1 | Manualshive

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OPERATOR’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 CONTAINED
THROUGHOUT.

And, most

importantly, think before you act
and be careful.

PIPELINER 200G

For use with machines having Code Numbers 10660; 10913; 11136

IM698-B

December, 2004

• 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 •

Copyright © 2004 Lincoln Global Inc.

This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specifications and availability of optional
features may have changed.

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Summary of Contents for PIPELINER 200G

Page 1: ...nd most importantly think before you act and be careful PIPELINER 200G For use with machines having Code Numbers 10660 10913 11136 IM698 B December 2004 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 Copyright 2004 Lincoln Global Inc T...

Page 2: ...S SHOULD CONSULT WITH THEIR 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 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...

Page 3: ...rth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h 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 3 i When...

Page 4: ...e 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 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 Cu...

Page 5: ...rans appropriés et non inflamma bles 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le la...

Page 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Page 7: ...____________________________________________________________________ Accessories Section C Optional Equipment Field Installed C 1 ________________________________________________________________________ Maintenance Section D Safety Precautions D 1 General Instructions D 1 Cooling System D 1 Engine Maintenance D 1 Bearings D 2 Commutator and Brushes D 2 Idle Control D 2 Nameplates D 2 Purging Air f...

Page 8: ... 46 HP 1600 RPM Low Idle 1360 INPUT GASOLINE ENGINE RATED OUTPUT WELDER HEIGHT WIDTH DEPTH WEIGHT 40 94 in 24 00 in 68 16in 1039 9 mm 609 6 mm 1731 0 mm 1295 0 lbs 587kg Top of enclosure add 4 6 116 8mm for exhaust OUTPUT GENERATOR Auxiliary Power 1 1 75 kW 15 Amps 120V DC PHYSICAL DIMENSIONS ENGINE OPERATING LOAD FUEL CONSUMPTION Coolant 9 9 Qts 9 4 Lts TECHNICAL SPECIFICATIONS Pipeliner 200G K60...

Page 9: ...o locate the welder so that engine exhaust fumes are properly vented to an outside area MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must be grounde...

Page 10: ... Cable Sizes for Combined Length of Electrode Plus Work Cable RECOMMENDED COPPER CABLE SIZES 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 Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport thi...

Page 11: ...ise connecting the battery to the battery cables the proper polarity must be observed The correct polarity is NEGATIVE GROUND CAUTION GASES FROM BATTERY can explode Keep sparks flame and cigarettes away BATTERY ACID can burn eyes and skin 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 ...

Page 12: ... the GM 3 0L industrial water cooled gasoline 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 Ignition switch Idler control switch hour meter a batte...

Page 13: ...es 130 F STOPPING THE ENGINE Turn the Ignition switch to OFF At the end of each day s welding refill the fuel tank to minimize moisture condensation in the tank Also run ning 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 Refer to engine Operation and Maintenance manual for additional information on the ...

Page 14: ...en designed to allow continuous year round operation Engine coolant is channeled through the TBI housing to prevent the build up of ice on the TBI throat around the throttle plate the elec tronic controller is programmed to automatically com pensate for the build up of ice on the throttle plate There will be no noticeable change in the operation of the welder should icing develop On start up there...

Page 15: ...ick operation containing remote control rheo stat and 100 ft 30 5m cable Easy Installation REMOTE CONTROL K2464 1 Contains remote control rheostst for adjusting the CC STICK OCV remote control potentiometer for adjusting the CV WIRE OCV and 100 ft 30 5m cable Easy Installation K953 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable federal state...

Page 16: ...aft at least once every month 8 See the engine manufacturers operation manual for detailed engine maintenance and troubleshoot ing instructions COOLING SYSTEM The Pipeliner 200G 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 ne...

Page 17: ... 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 b...

Page 18: ...ual for oil recommendations 4 Clean the air filter if the engine is operating in very dusty conditions NOTES Alternator belt Good Year 11AV0955 Fan belt Good Year 11AV1220 Alternator fan belt wear R Tension of alternator Fan belt I Drain fuel bowl Engine oil NOTE 1 3 R Engine oil level NOTE 1 Coolant NOTE 3 MAINTENANCE ITEM Concentration of antifreeze 50 50 water glycol mixture Radiator for contam...

Page 19: ... Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE 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 techni...

Page 20: ...r 2 Brushes may be worn down to limit 3 Field circuit may have variable resistance connection or intermit tent open circuit due to loose or broken wire 4 Electrode lead or work lead con nection may be poor 5 Wrong grade of brushes may have been installed on generator 6 Field rheostat may be making poor contact and overheating 1 Generator or exciter brushes may be loose or missing 2 Exciter may not...

Page 21: ... the commutator start the welder and the generator voltage should build up E 3 TROUBLESHOOTING E 3 PIPELINER 200G 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 p...

Page 22: ... Irregular and faulty fuel supply Injector pump trouble 5 Moisture or carbon on spark plugs 6 Improper viscosity of the lubricat ing oil 7 Clogged air cleaner 8 No compression 9 Engine protection light is ON 1 Air mixed in the fuel system 2 Uneven fuel injection Faulty fuel injector pump 3 Clogged fuel filter 4 Defective governor 5 Engine itself defective 1 Lack of fuel in the tank 2 Clogged fuel ...

Page 23: ...ng Lack of Power 1 Lack of Coolant 2 Loose or slipping fan belt 3 Damaged fan belt 4 Clogged radiator 5 Clogged radiator fan 6 Dust or scale clogged in the cool ing water passage 7 Faulty function in the thermostat 8 Overloading 9 Faulty TBI controller 1 Excess engine oil 2 Too low viscosity of the engine oil 1 Excess injection 2 Clogged air cleaner 3 Faulty function of the engine 1 Loose fan belt...

Page 24: ... throughout this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Surging Large Decrease in Speed Engine runs Irregularly Engine fails to pick up speed when Arc is struck 1 Dirty Air Filter 2 Engine running at RPM limiter 2000 RPM 1 Ice build up on throttle plate 1 Faulty coolant temperature sender 1 Faulty idler circuit If all recommended possible areas of ...

Page 25: ... Not O K Correct wiring With Idler Control Switch in the AUTO Position Engine Will Not Pick Up Speed When Auxiliary Load 1 Load too small Try load above 150 Watts 2 Check for loose or disconnected wire running from black lead out of exciter to CB2 circuit breaker The Arc is Struck Check for loose or disconnected wire running between weld selector switch and output stud Both 1 Check Idler circuit w...

Page 26: ...OTE CONTROL KIT TO CONNECTOR J5 ON THE MACHINE SEE BELOW SHOWN AS VIEWED FROM REAR CONTROL PANEL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 CURRENT SENSOR CAUTION DAMAGE CAN OCCUR TO THE REMOTE CONTROL SWITCH IF IT IS USED WITHOUT THE P11 PLUG INSTALLED OR A WIRE FEED MODULE INSTALLED ON PIPELINER 200G MACHINES CONNECT RED AND BLACK LEADS ON REMOTE TO E TO EXCITER OUTPUT RED AND BLACK LEADS ON MACHINE ...

Page 27: ...TAT ASSEMBLY INLINE CONNECTORS REMOTE CONTROL POTENTIOMETER BOX CONNECT TO CASE NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI K924 5 REMOTE CONTROL OPTIONAL SHOWN AS VIEWED FROM REAR CONTROL PANEL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 CURRENT SENSOR E TO EXCITER OUTPUT R B W 3 2 1 4 RESISTORS E RECEPTACLE B ELECTRICAL SYMBOLS LEAD COLOR CODE PER E1537 B BLACK OR GRAY R RED OR PINK W WHITE Y YELL...

Page 28: ...STORS Y X B G W F G ORANGE WHITE JUMPER WHITE JUMPER PIN CABLE CONNEC TION TABLE C D E LEAD COLOR RED BLUE CV WIRE CONTROL POT CCW BLUE RED ORANGE REMOTE CONTROL BOX CONNECT TO CASE K2464 1 REMOTE CONTROL WIRING CONNECTION DIAGRAM CC STICK CONTROL ...

Page 29: ... V I T Y W I T H O S 1 0 7 6 6 1 0 J J K K DIMENSION PRINT S 1 0 7 6 6 M E T R I C c m E N G L I S H i n 1 4 6 6 5 7 7 0 2 2 1 8 7 0 5 8 4 2 3 0 0 6 7 0 2 6 3 8 3 4 3 1 3 5 0 1 0 5 8 4 1 6 6 8 3 3 2 5 X A N B 1 5 4 5 6 T R A I L E R M O U N T I N G H O L E S 9 4 3 3 7 1 2 6 1 0 2 4 0 0 1 0 4 0 4 0 9 4 4 7 0 1 8 5 0 5 2 4 2 0 6 2 1 0 2 4 0 0 1 0 2 4 0 0 1 5 4 5 6 S K I D 1 5 4 5 6 S K I D M O U N T...

Page 30: ...NOTES PIPELINER 200G ...

Page 31: ...NOTES PIPELINER 200G ...

Page 32: ...electrically live parts or 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 moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 33: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 34: ...s 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 ...

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