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RETURN TO MAIN MENU
IM769
PIPELINER 200D
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 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.
OPERATOR'S MANUAL
Copyright © 2004 Lincoln Global Inc.
• 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
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric PIPELINER IM769
Summary of Contents for Lincoln Electric PIPELINER IM769
- Page 1 RETURN TO MAIN MENU IM769 PIPELINER 200D 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 ...
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
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. - Page 4 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.
- Page 5 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 The code number is especially important when identifying the correct replacement parts. - 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.
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Page 7: Table Of Contents
General Description ...B-1 Design Summary...B-1,B-2 Engine Operation...B-2 Starting the Perkins 104.22 Engine ...B-2 Stopping the Engine ...B-2 Typical Fuel Consumption ...B-2 Engine Break-In ...B-3 Welder Operation...B-3 Duty Cycle ...B-3 Control of Welding Current ...B-3 Idler Operation...B-4 Auxiliary Power...B-4 ________________________________________________________________________ Accessories ...Section C Optional Equipment (Field Installed) ...C-1... -
Page 8: Installation
Naturally Perkins @ 1600RPM Aspirated 104.22 Water Cooled Engine RATED OUTPUT @ 104°F(40C°) - WELDER DESCRIPTION VOLTS @ RATED AMPS 200 Amp DC Welder All Copper Windings Pure DC Power Generator RATED OUTPUT @ 104°F(40C°) - GENERATOR 1.80 kW, 15 Amps @ 120V DC @ 35% Duty Cycle... -
Page 9: Safety Precautions
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. -
Page 10: Trailers
“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 Amps Duty Cycle... -
Page 11: 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. -
Page 12: Operation
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”... -
Page 13: Engine Operation
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. -
Page 14: Engine Break-In
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. -
Page 15: Idler Operation
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” position, the idler solenoid acti- vates, and the engine goes to high idle speed. -
Page 16: Accessories
Trailer, K958-1 Ball Hitch, K958-2 Lunette Eye Hitch, K959-1 Fender & Light Kit. 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... -
Page 17: Maintenance
----------------------------------------------------------- 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. -
Page 18: Bearings
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... -
Page 19: Engine Service
1. Loosen by two or three turns, the vent screw (Figure D.1) on the fuel inlet connection. 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 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) -
Page 20: Troubleshooting
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 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. - Page 21 PROBLEMS (SYMPTOMS) Machine fails to hold the heat con- stantly. Welder starts but fails to generate current. Welding arc is loud and spatters excessively. 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.
- Page 22 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.
- Page 23 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine does not start or operates Irregularly Engine stops during operation and the Engine Protection light does not turn on Engine stops during operation and the Engine Protection light does turn on 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.
- Page 24 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 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) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your...
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Page 25: Electronic Idler Troubleshooting Guide
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 Open Measure DC Voltage on Idler Solenoid Coil 12 VDC Check Continuity of Current sensor from Idler PC Board Terminal... - Page 26 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 Does Not Pick Up Speed 1. Check Continuity of Idler Solenoid Coil (8.5-9.0 ohms) and Replace as Required.
- Page 27 DIAGRAMS SHUNT 610B PIPELINER 200D...
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Page 28: Diagrams
K2 K2464-1 REMOT W WIRING / NG / CONNECT RESISTORS REMOTE C CONTROL B ROL BOX THE LINCOLN ELECTRIC COMPANY DIAGRAMS REMOTE CONT CONTROL CONNECTION DI N DIAGRAM CV " "WIRE" CONT CONTROL P P OT CC " "STICK CK CONT... -
Page 29: Dimension Print
DIMENSION PRINT PIPELINER 200D... - Page 30 NOTES PIPELINER 200D...
- Page 31 NOTES PIPELINER 200D...
- Page 32 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 33 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 34 • 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...