Lincoln Electric Global Sites - IM698-B PIPELINER 200G · 2014-06-30 · December, 2004 • Sales and Service through Subsidiaries and Distributors Worldwide ... from the Lincoln

OPERATOR’S MANUAL

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

PIPELINER 200G For use with machines having Code Numbers 10660; 10913; 11136

IM698-BDecember, 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. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

PIPELINER 200G

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

Mar ‘95

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b.

PIPELINER 200G

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

PIPELINER 200G

ivSAFETYiv

Mar. ‘93PIPELINER 200G

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres 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 desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- 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 packetaccompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then“Product Registration”. Please complete the form and submit your registration.

vi vi TABLE OF CONTENTS

Page

Installation .........................................................................................................Section ATechnical Specifications ........................................................................................A-1Safety Precautions.................................................................................................A-1Exhaust Spark Arrester..........................................................................................A-2Location / Ventilation. ............................................................................................A-2Machine Grounding ...............................................................................................A-2Angle of Operation.................................................................................................A-3Lift Bail ..................................................................................................................A-3Trailers...................................................................................................................A-3Vehicle Mounting ...................................................................................................A-3Polarity Control and Cable Sizes...........................................................................A-3Pre-Operation Service ...........................................................................................A-4Oil... .......................................................................................................................A-4Fuel........................................................................................................................A-4Cooling System......................................................................................................A-4Battery Charging....................................................................................................A-4

________________________________________________________________________Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1General Description ...............................................................................................B-1Design Summary ...................................................................................................B-1Engine Operation...................................................................................................B-2

Starting the GM3.0L Engine ..............................................................................B-2Stopping the Engine ..........................................................................................B-2

Welder Operation...................................................................................................B-2Duty Cycle .........................................................................................................B-2Control of Welding Current ................................................................................B-3TBI Deicing Kit...................................................................................................B-3Idler Operation...................................................................................................B-3Auxiliary Power..................................................................................................B-3

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Equipment (Field Installed) .....................................................................C-1________________________________________________________________________

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1General Instructions ..............................................................................................D-1Cooling System .....................................................................................................D-1Engine Maintenance..............................................................................................D-1Bearings ................................................................................................................D-2Commutator and Brushes......................................................................................D-2Idle Control ...........................................................................................................D-2Nameplates ...........................................................................................................D-2Purging Air from Fuel System................................................................................D-2Engine Service Chart.............................................................................................D-3

________________________________________________________________________Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.............................................................................E-2 thru E-7

________________________________________________________________________Diagrams ..........................................................................................................Section F

Wiring Diagram..............................................................................................F-1, F-2Dimension Print.....................................................................................................F-3

________________________________________________________________________Parts Manual ............................................................................................................P370

________________________________________________________________________

DC CURRENT RANGEFine Adjustment in each Range

40-300 Amps

DUTY CYCLE

60%

60%

RATED DC OUTPUT*VOLTS @ RATED AMPS

Lincoln Plus Rating40V @ 200A

NEMA Rating28V @ 200A

A-1INSTALLATION

PIPELINER 200G

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 torated capacity. When welding, available auxiliary power will be reduced.

Make/Model Description Speed (RPM) Displacement Ignition Capacitiescu. in. (Ltrs.) System

High Idle 1600 Delco Voyager Fuel: 15 gal.4 Cylinder High Energy 57 Ltrs.

GM 4 Cycle3.0 Liter Full Load 1600 Distributor Type Oil: 4.5Qts.

Pipeliner 200G 183.0(3.0) Electronic 4.3 Ltrs. (K6090-7) 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 - GENERATORAuxiliary 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 (K6090-7)

DESCRIPTION

200 Amp DC Welder

All Copper Windings

Pure DC Power

Generator

Low Idle (1360 RPM)-No LoadHigh Idle (1600 RPM)-No Load

DC Auxiliary-128 Volts-15 Amps-1600 RPM50 Amps @ 38 Volts @ 60% Duty Cycle

100 Amps @ 34 Volts @ 60 % Duty Cycle150 Amps @ 29 Volts @ 60% Duty Cycle200 Amps @ 40 Volts @ 60 % Duty Cycle

.7 gal/hr (2.8 ltrs/hr)

.8 gal/hr (3.1 ltrs/hr)1.1 gal/hr (4.0 ltrs/hr)

1.04 gal/hr (3.94 ltrs/hr)1.12 gal/hr (4.25 ltrs/hr)1.15 gal/hr (4.37 ltrs/hr)1.34 gal/hr (5.07 ltrs/hr)

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC SHOCK can kill.• Do not touch electrically live parts or

electrode with skin or wet clothing.• Insulate yourself from work and

ground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open or

guards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information atfront of this operator’s manual.

-----------------------------------------------------------

WARNING

A-2INSTALLATION

PIPELINER 200G

A-2

PRE-OPERATION INSTALLATION

EXHAUST SPARK ARRESTER

Some federal, state, or local laws may require thatengines be equipped with exhaust spark arresterswhen they are operated in certain locations whereunarrested sparks may present a fire hazard. Thestandard mufflers included with these welders do notqualify as spark arresters. When required by local reg-ulations, suitable spark arrester must be installed andproperly maintained.

Use of an incorrect arrester may lead to engine dam-age or performance loss. Contact the engine manu-facturer for specific recommendations.----------------------------------------------------------------------

LOCATION / VENTILATIONAlways operate the welder with the doors closed.Leaving the doors open changes the designed air flowand may cause overheating.

The welder should be located to provide an unrestrict-ed flow of clean, cool air. Also, locate the welder sothat engine exhaust fumes are properly vented to anoutside area.

MACHINE GROUNDING

Because this portable engine driven welder creates itsown power, it is not necessary to connect its frame toan earth ground, unless the machine is connected topremises wiring (home, shop, etc.).

To prevent dangerous electric shock, other equipmentpowered by this engine driven welder must:

• be grounded to the frame of the welder using agrounded type plug,

or• be double insulated.

When this welder is mounted on a truck or trailer, itsframe must be securely connected to the metal frameof the vehicle. When this engine driven welder is con-nected to premises wiring such as that in a home orshop, its frame must be connected to the system earthground. See further connection instructions in the sec-tion entitled “Standby Power Connections” as well asthe article on grounding in the latest U.S. NationalElectrical Code and the local code.

In general, if the machine is to be grounded, it shouldbe connected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going intothe ground for at least ten feet and having no insulat-ed joints, or to the metal framework of a buildingwhich has been effectively grounded. The U.S.National Electrical Code lists a number of alternatemeans of grounding electrical equipment. A machinegrounding stud marked with the symbol is provid-ed on the front of the welder.

SAFETY PRECAUTIONS

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SUR-FACES.Where there is a combustible surface directly understationary or fixed electrical equipment, the surfaceshall be covered with a steel plate at least.06”(1.6mm) thick, which shall extend not more than5.90”(150mm) beyond the equipment on all sides.------------------------------------------------------------------------

CAUTION

A-3INSTALLATION

PIPELINER 200G

A-3

POLARITY CONTROL AND CABLE SIZES

With the engine off, route the electrode and workcables through the strain relief bracket on the baseand connect to the studs located below the fuel tankmounting rail. (see size recommendations below). ForPositive polarity, connect the electrode cable to theterminal marked “Positive”. For Negative polarity,connect the electrode cable to the “Negative” stud.These connections should be checked periodicallyand tightened if necessary.

When welding at a considerable distance from thewelder, be sure you use ample size welding cables.

LIFT BAILA lift bail is provided for lifting with a hoist.

TRAILERS (See ACCESSORIES SECTION)

If the user adapts a non-Lincoln trailer, he mustassume responsibility that the method of attachmentand usage does not result in a safety hazard, nordamage the welding equipment. Some of the factorsto be considered are as follows:1. Design capacity of trailer vs. weight of Lincoln

equipment and likely additional attachments.

2. Proper support of, and attachment to, the base ofthe welding equipment so there will be no unduestress to the framework.

3. Proper placement of the equipment on the trailer toensure stability side to side and front to back whenbeing moved and when standing by itself whilebeing operated or serviced.

4. Typical conditions of use, i.e., travel speed; rough-ness of surface on which the trailer will be operat-ed; environmental conditions; likely maintenance.

Amps

200

Duty Cycle

60%

Up to 200 ft(61.0m)

1

200-250 ft(61.0-72.2m)

1/0

Cable Sizes for CombinedLength 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 lawsregarding specific requirements for use on pub-lic highways.

VEHICLE MOUNTING

Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.

• Only transport this Equipment on serviceable vehi-cles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle isstable under conditions of use.

• Do not exceed maximum rated loads for compo-nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame ofvehicle.

• Follow vehicle manufacture’s instructions.------------------------------------------------------------------------

WARNING

ANGLE OF OPERATION

To achieve optimum engine performance the Pipeliner200G should be run in a level position. The maximumangle of operation for the engine is 60 degrees in adirection to cause the air intake manifold to be angledup, 45 degrees for the air intake manifold to be angleddown; and 50 degrees for the welder control panel tobe angled up or down. If the engine is to be operatedat an angle, provisions must be made for checkingand maintaining the oil level at the normal (FULL) oilcapacity in the crankcase. When operating the welderat an angle, the effective fuel capacity will be slightlyless than the specified 15 gallons.

• Lift only with equipment ofadequate lifting capacity.

• Be sure machine is stablewhen lifting.

• Do not lift this machine usinglift bale if it is equipped with aheavy accessory such as trail-er or gas cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------------

WARNING

A-4INSTALLATION

PIPELINER 200G

A-4

PRE-OPERATION SERVICE

READ the engine operating and maintenance instruc-tions supplied with this machine.------------------------------------------------------------

OIL

This unit is supplied from the factory with the enginecrankcase filled with a high quality SAE 10W/30 oil.This oil should be acceptable for most typical ambienttemperatures. Consult the engine operation manualfor specific engine manufacturers recommendations.Upon receipt of the welder, check the engine dipstickto be sure the oil is at the “full” mark. Add if required.DO NOT OVERFILL.

FUEL

Fill the fuel tank with the grade of fuel recommendedin the Engine Operator’s Manual. Make sure fuel valveon the sediment bowl is in the open position.

COOLING SYSTEM

The radiator has been filled at the factory with a 50-50mixture of ethylene glycol antifreeze and water.Check the radiator level and add a 50-50 solution asneeded. (See engine manual or antifreeze containerfor alternate antifreeze recommendations.)

BATTERY CHARGING

The Pipeliner 200G is equipped with a wet chargedbattery. The charging current is automatically regulat-ed when the battery is low (after starting the engine)to a trickle current when the battery is fully charged.

When replacing, jumping, or otherwise connecting thebattery to the battery cables the proper polarity mustbe observed. The correct polarity is NEGATIVEGROUND.

CAUTIONGASES FROM BATTERY can explode.• Keep sparks, flame and cigarettesaway.

BATTERY ACID can burn eyes andskin.• Wear gloves and eye protection andbe careful when boosting, charging orworking near battery.

To prevent EXPLOSION when:a) Installing a new battery - disconnect the

negative cable from the old battery first and connect the negative cable to the new battery last.

b) Connecting a battery charger - remove the battery from the welder by disconnecting the negative cable first, then the positive cable and battery clamp. When reinstalling, connect the negative cable last.

c) Using a booster - connect the positive lead to the battery first, then connect the negative lead to the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:a) Installing a new battery.b) Using a booster.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, turn ignitionswitch off when engine is not running.

• To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug.

------------------------------------------------------------------------

WARNING

• Stop engine while fueling.• Do not smoke when fueling.• Keep sparks and flame away

from tank.• Do not leave unattended while

fueling.• Wipe up spilled fuel and allow

fumes to clear before startingengine.

• Do not overfill tank, fuel expan-sion may cause overflow.

GASOLINE FUEL ONLY------------------------------------------------------------------------

WARNING

GASOLINEcan cause fireor explosion.

B-1OPERATIONB-1

SAFETY PRECAUTIONS

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------








------------------------------------------------------------------------

See additional warning information atfront of this operator’s manual.

------------------------------------------------------------Operate the welder with the doors closed. Leavingthe doors open changes the designed air flow andcan cause overheating.------------------------------------------------------------------------

GENERAL DESCRIPTION

The Pipeliner 200G is a heavy duty engine driven DCarc welding power source capable of providing DCconstant current output for stick welding and DC TIGwelding. With the addition of the optional K623-1 WireFeed Module the Pipeliner 200G will provide constantvoltage output for running the LN-25 wire feeder.

The Pipeliner 200G has a current range of 40-300 DCamps with output ratings as follows:

RATED OUTPUT DUTY CYCLE

200A @ 28V 60%200A @ 40V 60%

The units are also capable of providing 1.75 kw of115V DC auxiliary power.This unit uses the GM 3.0L industrial water- cooledgasoline engine.

DESIGN SUMMARY

Control Panel

Both the engine and the welder controls are locatedon one recessed panel at the exciter end of themachine. The welder controls consist of a five step“Current Range Selector” switch and a “Fine CurrentAdjustment” rheostat. The welder is equipped with a“Start” button, “Ignition” switch, “Idler” control switch,hour meter, a battery charging ammeter, an oil pres-sure gauge and engine coolant temperature gauge.

The control panel also contains a three prong ground-ing type receptacle for auxiliary power.

Welding Generator

The Pipeliner 200G uses the old style, round, all cop-per FJW Generator frame which provides the cus-tomer with the original “Classic” pipe welding arc.

Engine Idler

The Pipeliner 200G is equipped with an electronicautomatic engine idler. It automatically increases anddecreases engine speed when starting and stoppingwelding or using auxiliary power. A built-in time delaypermits changing electrodes before the engine slowsto its low idle speed. The “Idler” control switch on thepanel locks the idler in the full speed position whendesired.

Auxiliary Power

1.75 kw of nominal 120V DC. Output voltage is main-tained within ± 10% at all loads up to rated capacity.(See Optional Features for power plug kits).

Welder Enclosure

The complete welder is rubber mounted on a ruggedsteel “C” channel base.

The output terminals are placed at the side of themachine so that they are protected by the door. Theoutput terminals are labeled (+) and (-).

Ignition System

A High Energy Distributor Type electronic ignition isstandard.

PIPELINER 200G

WARNING

B-2OPERATIONB-2

PIPELINER 200G

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 arestandard.

Engine Hour Meter

A meter to record the hours of operation.

High Idle RPM (OCV) Adjustment- A potentiometeris mounted on the output rail that allows the operatorto adjust the high idle engine speed between 1500and 1600 RPM in 20 RPM increments. This is to allowfurther adjustment of the OCV. Total OCV adjustmentrange is about 10 Volts.

ENGINE OPERATION

STARTING THE GM 3.0L ENGINE

• Turn the Idler control switch to “HIGH”. (Optional)

• Turn the Ignition switch to “ON”.

• Press the “Start” button.

• If the engine fails to start in 20 seconds, wait 30seconds before repeating the above procedure.

• Allow the engine to run at high idle speed for sever-al minutes to warm up. If idle control switch is left in“Auto” position , engine will run at 1600 RPM untilengine coolant temperature reaches 130°F.

STOPPING THE ENGINE

• Turn the Ignition switch to “OFF”.

At the end of each day’s welding, refill the fuel tank tominimize 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 thefuel feed valve beneath the fuel tank. Refer to engine“Operation and Maintenance manual” for additionalinformation on the engine supplied with this welder.

WELDER OPERATION

DUTY CYCLE

The NEMA output rating of the Pipeliner 200G is 200amperes at 28(1) arc volts on a 60% duty cycle. Dutycycle is based on a ten minute period; thus, thewelder can be loaded at rated output for six minutesout of every ten minute period.

(1) The Lincoln “plus output” rating at 60% duty cycleis 200 amperes at 40 Volts.


electrode with skin or wet clothing.• Insulate yourself from work and ground.

FUMES & GASES can be dangerous.• Keep your head out of the fumes.• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire orexplosion.• Keep flammable material away.

ARC RAYS can burn.• Wear eye, ear, and body protection.

WARNING

B-3OPERATIONB-3

PIPELINER 200G

CONTROL OF WELDING CURRENT

DO NOT TURN THE “CURRENT RANGE SELEC-TOR” WHILE WELDING because the current mayarc between the contacts and damage the switch.------------------------------------------------------------------------The “Current Range Selector” provides five overlap-ping current ranges. The “Fine Current Adjustment”adjusts the current from minimum to maximum withineach range. Open circuit voltage is also controlled bythe “Fine Current Adjustment” permitting control of thearc characteristics.

A high open circuit voltage setting provides the soft“buttering” arc with the best resistance to pop-outspreferred for most welding. To get this characteristic,set the “Current Range Selector” to the lowest settingthat still provides the current you need and set the“Fine Current Adjustment” near maximum. For example: toobtain 175 amps and a soft arc, set the “Current RangeSelector” to the 190-120 position and then adjust the “FineCurrent Adjustment” for 175 amps.When a forceful “digging” arc is required, usually forvertical and overhead welding, use a higher “CurrentRange Selector” setting and lower open circuit volt-age. For example: to obtain 175 amps and a forcefularc, set the “Current Range Selector” to the 240-160position and the “Fine Current Adjustment” setting toget 175 amps.

DO NOT attempt to set the “Current Range Selector”between the five points designated on the nameplate.------------------------------------------------------------------------These switches have a spring loaded cam whichalmost eliminates the possibility of setting this switchbetween the designated points.

TBI DEICING SYSTEMThe welder has been designed to allow continuousyear-round operation. Engine coolant is channeledthrough the TBI housing to prevent the build up of iceon 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 ofthe welder should icing develop. On start-up, there isa possibility for the engine to overspeed (to a maxi-mum of 2000 RPM) for up to 10 seconds after throttlebody icing conditions have occurred. The electronicgovernor will correct itself for the new operating condi-tions and normal operation will resume.

IDLER OPERATIONThe operating speeds are as follows:

The idler is controlled by the “Idler” toggle switch onthe welder control panel. The switch has twopositions as follows:

1. In the “High” position, the idler is off, and theengine runs at the high speed controlled by thegovernor. This speed can be adjusted between1500 and 1600 RPM using the RPM dial on theoutput rail.

2. In the “Automatic” / position, theidler operates as follows:

• When welding or drawing power for lights ortools (approximately 100-150 watts minimum)from the receptacle, the engine operates at thespeed, set by the RPM dial.

• When welding ceases or the power load isturned off, a preset time delay of 10 secondsstarts. This time delay cannot be adjusted.

• If the welding or power load is not re-startedbefore the end of the time delay, the idler reducesthe engine to low idle speed.

AUXILIARY POWER

1.75 kw of 120V DC auxiliary power is available at thereceptacle located on the control panel.

CAUTION

CAUTION

ORDERINGINFO.

ENGINE FULLLOAD

HIGHIDLE

LOWIDLE

K6090-7 GM 3.0L 1600-1500

1600-1500

1360

C-1ACCESSORIESC-1

PIPELINER 200G

OPTIONAL EQUIPMENT (FIELD INSTALLED)

(K704) Accessory Set

Includes 35 ft (10.7m) electrode and 30 ft (9.1m) workcables, headshield, work clamp, and electrode holder.

Pipe Thawing with an arc welder can cause fire,explosion, damage to electric wiring or to the arcwelder if done improperly. The use of an arcwelder for pipe thawing is not approved by theCSA, nor is it recommended or supported byLincoln Electric.------------------------------------------------------------------------(K924-4) REMOTE CONTROL

For machines having Code Number 10660:For “Stick” operation which contains switch, remotecontrol rheostat and 100 ft (30.5m) or 25 ft (7.6m)cable. Easy Installation.

(K924-5) REMOTE CONTROL

For machines having Code Number 10913:For “Stick” operation containing remote control rheo-stat and 100 ft (30.5m) cable. Easy Installation.

REMOTE CONTROL (K2464-1) - Containsremote control rheostst (for adjusting the CC“STICK” OCV), remote control potentiometer(for adjusting the CV “WIRE” OCV), and 100ft. (30.5m) cable. Easy Installation>

(K953-1) TRAILER - Two-wheeled trailer withoptional fender and light package. For highway use,consult applicable federal, state, and local lawsregarding possible additional requirements. There is achoice of 2 hitches, a fender & a light package. Order:K953-1 TrailerK958-1 Ball HitchK958-2 Lunette Eye Hitch K959-1 Fender & Light KitK965-1 Cable Rack

(K623-1) WIRE FEED MODULE -Provides con-stant voltage (CV) output with improved arc stabilityfor Innershield welding. Also, excellent for MIG weld-ing. Easy Installation. Recommended wire feeder isthe LN-25.

(K2261-1) OIL DRAIN KIT-Includes ball valve,hose and clamp.

WARNING

D-1MAINTENANCED-1

PIPELINER 200G

SAFETY PRECAUTIONS

GENERAL INSTRUCTIONS

1. Blow out the welder and controls with an air hoseat least once every two months. In particularly dirtylocations, this cleaning may be necessary once aweek. Use low pressure air to avoid driving dirt intothe insulation.

2. “Current Range Selector” contacts should not begreased. To keep the contacts clean, rotate thecurrent control through its entire range frequently.Good practice is to turn the handle from maximumto minimum setting twice each morning beforestarting to weld.

3. Change the crankcase oil and oil filter after the first50 hours of operation and thereafter at regularintervals using the proper grade of oil. See the rec-ommendations in the engine operation manual.

4. Inspect the air filter daily - - more often in dustyconditions when necessary clean or replace. Theair filter should never be removed while the engineis running. The air filter element part number isDonaldson #181050 or Nelson #70206N.

5. When necessary, remove the sediment bowl frombeneath the gas tank and clean out any accumulat-ed dirt and water. Replace the fuel filter in the fuelline as needed. In an emergency, the fuel filter canbe back-flushed for continued use until a replace-ment can be obtained.

6. Fan belts tend to loosen after the first 50 hours ofoperation. Check engine operation manual andtighten if necessary. DO NOT OVERTIGHTEN.

7. Put a drop of oil on the “Current Range Selector”shaft at least once every month.

8. See the engine manufacturers operation manualfor 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 ofcoolant. Clean and flush the cooling system periodi-cally to prevent clogging the passage and overheatingthe engine. When antifreeze is needed, always usethe permanent type. Capacity = 9.9 Qty. (9.4 liter)Consult the engine owners manual for the proper fre-quency and procedure.

ENGINE MAINTENANCE

Refer to the Engine’s operation and mainte-nance manual for additional information onthe engine.

Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may be neces-sary to remove safety guards to performrequired maintenance. Remove guards onlywhen necessary and replace them when themaintenance requiring their removal is com-plete. Always use the greatest care when work-ing near moving parts.

Do not put your hands near the engine coolingblower fan. If a problem cannot be corrected byfollowing the instructions, take the machine tothe nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------ELECTRIC SHOCK can kill.• Do not touch electrically live parts or







------------------------------------------------------------------------See additional warning information atfront of this operator’s manual.

-----------------------------------------------------------

WARNING

D-2MAINTENANCED-2

PIPELINER 200G

BEARINGS

This welder is equipped with a double-shielded ballbearing having sufficient grease to last indefinitelyunder 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. Apad of grease one inch wide, one inch long, and oneinch high weighs approximately one-half ounce.Over-greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of thearea. Wipe the fittings completely clean and use cleanequipment. More bearing failures are caused by dirtintroduced during greasing than from insufficientgrease.

COMMUTATOR AND BRUSHES

Uncovered rotating equipment can be dangerous.Use care so your hands, hair, clothing or tools donot catch in the rotating parts. Protect yourselffrom particles that may be thrown out by the rotat-ing armature when stoning the commutator.------------------------------------------------------------------------The generator brushes are properly adjusted when thewelder is shipped. They require no particular attention.DO NOT SHIFT THE BRUSHES or adjust the rockersetting. Shifting of the brushes may result in:

• Change in machine output• Commutator damage• Excessive brush wear

Periodically inspect the commutator and brushes byremoving the covers. DO NOT remove or replacethese covers while the machine is running.

Commutators require little attention. However, if theyare black or appear uneven, have them cleaned by anexperienced maintenance man using fine sandpaperor a commutator stone. Never use emery cloth orpaper for this purpose.

Replace brushes when they wear within 1/4” of thepigtail. A complete set of replacement brushes shouldbe kept on hand. Lincoln brushes have a curved faceto fit the commutator. Have an experienced mainte-nance man seat these brushes by lightly stoning thecommutator as the armature rotates at full speed untilcontact is made across the full face of the brushes.After stoning, blow out the dust with low pressure air.

Arcing or excessive exciter brush wear indicates apossible misaligned shaft. Have an authorized FieldService Shop check and realign the shaft.IDLE CONTROL MAINTENANCEBefore doing electrical work on the idler printedcircuit board, disconnect the battery.------------------------------------------------------------------------

1. Proper operation of the idler requires good ground-ing of the battery and TBI controller.

2. If desired, the welder can be used without automat-ic idling by setting the “Idler” switch to the “HighIdle” position.

3. When installing a new battery or using a jumperbattery to start the engine, be sure the batterypolarity is connected properly. The correct polarityis negative ground. Damage to the engine alterna-tor and the TBI controller board can result fromincorrect connection.

NAMEPLATES

Whenever routine maintenance is performed on thismachine - - or at least yearly - - inspect all nameplatesand labels for legibility. Replace those which are nolonger clear. Refer to the parts list for the replacementitem number.

PURGING AIR FROM FUEL SYSTEM

The fuel system operates as follows: The fuel pumpwill operate for a maximum of 3 seconds when theignition switch is turned “ON”. The pump will restartonce the start button is pushed and continue when theengine starts. To purge the system of air if fuel lineshave been removed, the ignition switch can be tog-gled “ON” and “OFF” (at 3 second intervals) until fuelflows through the fuel return line in the neck of the fuelline.

WARNING

CAUTION

D-3MAINTENANCED-3

PIPELINER 200G

I

EVERY 600 HOURS OR 12 MONTHS

EVERY 200 HOURS OR 6 MONTHSEVERY 100 HOURS OR 3 MONTHS

FIRST SERVICE-(50 HOURS)EVERY DAY OR EVERY 8 HOURS

If necessary use shorter periods.These preventive maintenance periods apply to average conditions of operation.

PSI #32500292

AC PF25

TYPE OR QUANTITY

Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.

4.5qrts, (4.3L) (including filter)

(3) Fill slowly! Ensure correct quantity is used.(2) Consult Engine Operators Manual for additional maintenance schedule information.

9.9qrts, (9.4L)

(1) Consult Engine Operators Manual for oil recommendations.

(4) Clean the air filter if the engine is operating in very dusty conditions.

NOTES:

Alternator belt Good Year 11AV0955Fan belt Good Year 11AV1220

Alternator / fan belt wear

R

Tension of alternator / Fan beltI

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 mixtureRadiator for contamination or blockage

C

I

R

Coolant level

R

C

RR

II

R

ENGINE SERVICE

I

Fuel filter canister

S20919-3

BCI GROUP 45

Donaldson #P181050 or Nelson #70206N

4 - AC R46TS

R = ReplaceC = Clean

BatteryLeaks or engine damage

I

Air filter element

All nuts and bolts for tightness

I = Inspect

Electrical systems

R

4 C C

Spark Plugs (Gap = 0.040")

I

Tighten cylinder head

I

I

R

Air filter (earlier check may be req'd.)

R

I

Engine oil filter

ENGINE SERVICE (NOTE 2)

E-1TROUBLESHOOTINGE-1

PIPELINER 200G

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal 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 technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

ELECTRIC SHOCK can kill.• Do not touch electrically live parts such as output

terminals or internal wiring.

ENGINE EXHAUST can kill.• Use in open, well ventilated areas or vent exhaust

outside.

MOVING PARTS can injure.• Do not operate with doors open or guards off.• Stop engine before servicing.• Keep away from moving parts.

• Remove guards only when necessary and replace when workrequiring removal is complete.

• Only qualified personnel should install, use or service thisequipment.


PIPELINER 200G

Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSES

RECOMMENDEDCOURSE OF ACTION

Machine fails to hold the heat con-stantly.

Welder starts but fails to generatecurrent.

Welding arc is loud and spattersexcessively.

1. Rough or dirty commutator.

2. Brushes may be worn down tolimit.

3. Field circuit may have variableresistance connection or intermit-tent open circuit due to loose, orbroken wire.

4. Electrode lead or work lead con-nection may be poor.

5. Wrong grade of brushes mayhave been installed on generator.

6. Field rheostat may be makingpoor contact and overheating.

1. Generator or exciter brushes maybe loose or missing.

2. Exciter may not be operating.

3. Field circuit of generator orexciter may be open.

4. Exciter may have lost excitation.

5. Series field and armature circuitmay be open-circuited.

1. Current setting may be too high.

2. Polarity may be wrong.

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

Flashing the exciter field consists of passing current through the fields using an external source of 6 to 125 voltsof DC power from a storage battery or DC generator. If using a DC generator, keep the generator turned offexcept when actually applying the flashing current. To flash the fields:

1. Turn the welder off. Raise one exciter brush off the commutator.

2. On Lincoln welders, attach the positive lead from the external DC source to the right hand brushholder.

3. Carefully holding an insulated section of the negative lead from the DC source, touch its lug or clamp to theleft 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 thegenerator voltage should build up.


PIPELINER 200G



CAUTION

PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLECAUSES


Welding current too great or toosmall compared to indication on thedial.

Arc continuously pops out.

1. Exciter output low causing lowoutput compared to dial indica-tion.

2. Operating speed too low or high.

1. “Current Range Selector” switchmay be set at an intermediateposition.


JULY97


PIPELINER 200G


CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)


Engine does not start

Irregular running of the Engine.

Engine stops running DuringOperation and the Engine ProtectionLight Does Turn On. (Solid Light)

1. Faulty Ignition switch

2. Insufficient charging or complete dis-charge of the battery Charge.

3. Lack of fuel or Air mixed in thefuel system.

2. Clogged fuel filter.

4. Irregular and faulty fuel supply(Injector pump trouble)

5. Moisture or carbon on sparkplugs.

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 fuelinjector pump).


4. Defective governor.

5. Engine itself defective.

1. Lack of fuel in the tank.




5. Lack of Engine Oil.

6. Fault in oil pressure switch.

7. Oil leakage from the lubricatingsystem.

8. Clogged oil filter.

9. Oil too light.

10. Faulty TBI controller.

11. Faulty function of the engine.




PIPELINER 200G


CAUTION


PROBLEMS(SYMPTOMS)



Engine Stops During Operation andthe Engine Protection Light DoesTurn On. (Flashing)

White or Blue Smoke.

Dark Smoke

Faulty Charging

Starter Motor does not run.

Engine Knocking.

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.2. Faulty wiring.3. Faulty battery.4. Worn out alternator brush.

1. Loose or damaged wiring.2. Low Battery voltage.3. Damaged starter motor.

1. Poor grade of Gasoline.2. Spark advance to far.

1. Carbon deposits causing pre-igni-tion.

2. Incorrect timing.



PIPELINER 200G


CAUTION


PROBLEMS(SYMPTOMS)



Surging

Large Decrease in Speed.

Engine runs Irregularly.

Engine fails to pick up speed whenArc is struck.

1. Dirty Air Filter.

2. Engine running at RPM limiter(2000 RPM).

1. Ice build up on throttle plate.

1. Faulty coolant temperaturesender.

1. Faulty idler circuit.



PIPELINER 200G

ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE

Engine Will Not Return to Low Idle in Approximately 10 Seconds

After Welding and Auxiliary Loads are Removed

Set Idler Control Switchto the Auto Position

Check for Continuity through IdlerControl Switch

Open Closed

Remove Molex connector Replace Idlerfrom current sensing board. Control Switch.

Operation Same Machine IdlersCheck wiring between TBI controller and current sensing board. 1. Check for current in wires looping through

current sensor.2. Replace current sensor.

Have TBI controller inspected at authorized service shop. 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 loadabove 150 Watts.

2. Check for loose ordisconnected wire runningfrom black lead out of exciterto CB2 circuit breaker.

The Arc is Struck

Check for loose or disconnectedwire running between weldselector switch and output stud.

Both

1. Check Idler circuit wiring. Possibleproblems are wires from CurrentSensing Board reversed at idlerswitch or wires connected incorrectlyat Current Sensor Molex plug.

2. Replace current Sensing Board.


CAUTION

F-1DIAGRAMSF-1

PIPELINER 200G

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NOTES

PIPELINER 200G

NOTES

PIPELINER 200G

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

� Do not touch electrically live parts orelectrode with skin or wet clothing.

� Insulate yourself from work andground.

� No toque las partes o los electrodosbajo 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 contactavec des pièces sous tension.

� Isolez-vous du travail et de la terre.

� Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

� Isolieren Sie sich von denElektroden und dem Erdboden!

� Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

� Isole-se da peça e terra.

� Keep flammable materials away.

� Mantenga el material combustiblefuera del área de trabajo.

� Gardez à l’écart de tout matérielinflammable.

� Entfernen Sie brennbarres Material!

� Mantenha inflamáveis bem guarda-dos.

� Wear eye, ear and body protection.

� Protéjase los ojos, los oídos y elcuerpo.

� Protégez vos yeux, vos oreilles etvotre corps.

� Tragen Sie Augen-, Ohren- und Kör-perschutz!

� Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

� Keep your head out of fumes.� Use ventilation or exhaust to

remove fumes from breathing zone.

� Los humos fuera de la zona de res-piración.

� Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

� Gardez la tête à l’écart des fumées.� Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

� Vermeiden Sie das Einatmen vonSchweibrauch!

� Sorgen Sie für gute Be- undEntlüftung 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 máquinaantes de iniciar cualquier servicio.

� Débranchez le courant avant l’entre-tien.

� Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

� Não opere com as tampas removidas.� Desligue a corrente antes de fazer

serviço.� Não toque as partes elétricas nuas.

� Do not operate with panel open orguards off.

� No operar con panel abierto oguardas quitadas.

� N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

� Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

� Mantenha-se afastado das partesmoventes.

� Não opere com os paineis abertosou guardas removidas.

• 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 •

Documents

Lincoln Electric Global Sites - IM698-B PIPELINER 200G · 2014-06-30 · December, 2004 • Sales and Service through Subsidiaries and Distributors Worldwide ... from the Lincoln