Manuel d'utilisation / d'entretien du produit PIPELINER 200 du fabricant Lincoln Electric
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PIPELINER 200 SVM193-A July , 2009 For use with machines having Code Numbers: 1 1 1 14, 1 1316, 1 1471 10929, 10660, 10913, 1 1 136 ® SER VICE MANUAL • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.
PIPELINER® 200 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
PIPELINER® 200 SAFETY ii ii FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
PIPELINER® 200 SAFETY iii iii Jan ʻ09 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ʼs recommendations.
SAFETY iv iv PIPELINER® 200 Mar ʻ93 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 ʼArc 1.
I I - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - PIPELINER® 200 Page S a f e t y ........................................................................... i - i v Installation (Kubota V2203M) (K6090-1 1) ......................................... Section A Installation (Perkins 104.
T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 PIPELINER® 200D KUBOT A I n s t a l l a t i o n ............................................................................. A - 1 T e c h n i c a l S p e c i f i c a t i o n s ....................
INST ALLA TION A-2 A-2 PIPELINER® 200D KUBOT A TECHNICAL SPECIFICA TIONS - PIPELINER® 200D KUBOT A (K6090-1 1) INPUT - DIESEL ENGINE RA TED OUTPUT @ 104°F(40°C) - WELDER HEIGHT WIDTH DEPTH WEIGHT 45.
INST ALLA TION A-3 A-3 PIPELINER® 200D KUBOT A ENGINE IDLER The Pipeliner® 200D KUBOT A is equipped with an electronic automatic engine idler . It automatically increases and decreases engine speed when starting and stopping welding or using auxiliary power .
INST ALLA TION A-4 A-4 PIPELINER® 200D KUBOT A PRE-OPERA TION INST ALLA TION EXHAUST SP ARK ARRESTER Some federal, state or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard.
INST ALLA TION A-5 A-5 PRE-OPERA TION SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. OIL This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures.
INST ALLA TION A-6 A-6 PIPELINER® 200D KUBOT A Battery Charging The PIPELINER® 200D KUBOT A is equipped with a wet charged battery . The charging current is automat- ically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.
T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 PIPELINER® 200D KUBOT A O p e r a t i o n .............................................................................. B - 1 E n g i n e O p e r a t i o n .............................................
OPERA TION B-2 B-2 ENGINE OPERA TION Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. ST ARTING THE PIPELINER® 200D KUBOT A V2203M DIESEL ENGINE 1. T urn the “IDLER” switch to “HIGH”.
OPERA TION B-3 B-3 PIPELINER® 200D KUBOT A WELDER OPERA TION ------------------------------------------------------------------------ DUTY CYCLE The NEMA output rating of the PIPELINER® 200D KUBOT A is 200 amperes at 28 arc volts on a 60% duty cycle (consult Specifications in this manual for alternate ratings).
OPERA TION B-4 B-4 PIPELINER® 200D KUBOT A IDLER OPERA TION Start the engine with the “Idler” switch in the “High” position. Allow it to run at high idle speed for several minutes to warm the engine. See Specifications for operating speeds. The idler is controlled by the “Idler” toggle switch on the welder control panel.
T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 PIPELINER® 200D KUBOT A A c c e s s o r i e s............................................................................ C - 1 O p t i o n a l F e a t u r e s..........................................
ACCESSORIES C-2 C-2 PIPELINER® 200D KUBOT A WIRE FEED OPTIONS Wire Feed Module (K623-1) - Provides constant volt- age (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25.
T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 PIPELINER® 200D KUBOT A M a i n t e n a n c e ........................................................................... D - 1 Safety Precautions, Bearings, Commutator & Brushes, . . . . . . . . .
MAINTENANCE D-2 D-2 SAFETY PRECAUTIONS GENERAL INSTRUCTIONS 1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation.
MAINTENANCE D-3 D-3 PIPELINER® 200D KUBOT A Replace brushes when they wear within 1/4”(3.5mm) of the pigtail. A complete set of replacement brushes should be kept on hand.
MAINTENANCE D-4 D-4 PIPELINER® 200D KUBOT A If necessary use shorter periods. These preventive m aintenance periods apply to average conditions of operation. Above operations to be carried out by trained personnel with reference to the worksh op manual where necessary.
MAINTENANCE D-5 D-5 PIPELINER® 200D KUBOT A 9 9 8 8 1 1 5 5 7 7 4 4 6 6 3 3 6 6 9 9 2 2 Figure D.2 - Major Component Location 1. Case Front Assembly 2. Engine Assembly 3. Exciter Frame, Armature Assembly 4. Generator Frame, Armature & Coupling 5.
NOTES D-6 D-6 PIPELINER® 200D KUBOT A Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to .
T ABLE OF CONTENTS - INST ALLA TION SECTION AA-1 AA-1 PIPELINER® 200D PERKINS I n s t a l l a t i o n ........................................................................... A A - 1 T e c h n i c a l S p e c i f i c a t i o n s ..................
INST ALLA TION AA-2 AA-2 DC CURRENT RANGE Fine Adjustment in each Range 40-300 Amps DUTY CYCLE* 60% RA TED DC OUTPUT VOL TS @ RA TED AMPS Lincoln Plus Rating 40V @ 200A NEMA Rating 28V @ 200A PIPELINER® 200D PERKINS 1. Output rating in watts is equivalent to volt-amperes at unity power factor .
INST ALLA TION AA-3 AA-3 Do not attempt to use this equipment until you have thoroughly read the engine manufacturer ʼ s manual supplied with your welder . It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
INST ALLA TION AA-4 AA-4 PIPELINER® 200D PERKINS POLARITY CONTROL AND CABLE SIZES With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mount- ing rail.
INST ALLA TION AA-5 AA-5 PIPELINER® 200D PERKINS OIL This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the engine operation manual for specific engine manufacturers recommendations.
NOTES AA-6 AA-6 PIPELINER® 200D PERKINS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t.
T ABLE OF CONTENTS - OPERA TION SECTION BB-1 BB-1 PIPELINER® 200D PERKINS O p e r a t i o n ............................................................................ B B - 1 S a f e t y P r e c a u t i o n s &D e s i g n S u m m a r y ........
The Pipeliner® 200D has a current range of 40-300 DC amps with output ratings as follows: RA TED OUTPUT DUTY CYCLE 200A @ 28V 60% 200A @ 40V 60% The unit is also capable of providing 1.80 kw of 120V DC auxiliary power at 35% duty cycle maximum. This unit uses the PERKINS 104.
OPERA TION BB-3 BB-3 PIPELINER® 200D PERKINS Cranking System A 12V electric starter is standard. Air Cleaner Heavy duty two-stage dry type Exhaust A muffler and stainless steel exhaust outlet pipe are standard. Engine Hour Meter A meter to record the hours of operation.
OPERA TION BB-4 BB-4 ENGINE BREAK-IN Lincoln Electric selects high quality , heavy-duty indus- trial engines for the portable welding machines we offer .
OPERA TION BB-5 BB-5 PIPELINER® 200D PERKINS When a forceful “digging” arc is required, usually for vertical and overhead welding, use a higher “Current Range Selector” setting and lower open circuit voltage.
NOTES BB-6 BB-6 PIPELINER® 200D PERKINS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t.
T ABLE OF CONTENTS - ACCESSORIES SECTION CC-1 CC-1 PIPELINER® 200D PERKINS A c c e s s o r i e s .......................................................................... C C - 1 O p t i o n a l F e a t u r e s ......................................
ACCESSORIES CC-2 CC-2 PIPELINER® 200D PERKINS OPTIONAL FEA TURES (Field Installed) Accessory Set (K704) - Includes electrode and work cables, headshield, work clamp and electrode holder . Remote Control Kit (K924-5) - Contains a remote control rheostat and 100 ft (30.
T ABLE OF CONTENTS - MAINTENANCE SECTION DD-1 DD-1 PIPELINER® 200D PERKINS M a i n t e n a n c e .......................................................................... D D - 1 S a f e t y P r e c a u t i o n s ....................................
MAINTENANCE DD-2 DD-2 PIPELINER® 200D PERKINS SAFETY PRECAUTIONS GENERAL INSTRUCTIONS 1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation.
MAINTENANCE DD-3 DD-3 PIPELINER® 200D PERKINS BEARINGS This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal service. Where the welder is used con- stantly or in excessively dirty locations, it may be nec- essary to add one-half ounce of grease per year .
MAINTENANCE DD-4 DD-4 PIPELINER® 200D PERKINS I EVERY 400 HOURS OR 12 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 100 HOURS OR 3 MONTHS FIRST SERVICE-(20 / 50 HOURS) EVERY DAY OR EVERY 8 HOURS Perkins #140517000 If necessary use shorter periods. These preventive maintenance periods apply to average conditions of operation.
MAINTENANCE DD-5 DD-5 PIPELINER® 200D PERKINS 10 9 1 5 7 4 6 3 10 2 8 Figure DD.2 - Major Component Location 1. Case Front Assembly 2. Engine Assembly 3. Exciter Frame, Armature Assembly 4. Generator Frame, Armature & Coupling 5. Fuel T ank Assembly 6.
NOTES DD-6 DD-6 PIPELINER® 200D PERKINS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t.
T ABLE OF CONTENTS - INST ALLA TION SECTION AAA-1 AAA-1 PIPELINER® 200G I n s t a l l a t i o n .......................................................................... A A A - 1 T e c h n i c a l S p e c i f i c a t i o n s .......................
INST ALLA TION AAA-2 AAA-2 DC CURRENT RANGE Fine Adjustment in each Range 40-300 Amps DUTY CYCLE 60% 60% RA TED DC OUTPUT* VOL TS @ RA TED AMPS Lincoln Plus Rating 40V @ 200A NEMA Rating 28V @ 200A PIPELINER® 200G 1. Output rating in watts is equivalent to volt-amperes at unity power factor .
INST ALLA TION AAA-3 AAA-3 Do not attempt to use this equipment until you have thoroughly read the engine manufacturer ʼ s manual supplied with your welder . It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
INST ALLA TION AAA-4 AAA-4 PIPELINER® 200G POLARITY CONTROL AND CABLE SIZES With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mount- ing rail. (see size recommendations below).
INST ALLA TION AAA-5 AAA-5 PIPELINER® 200G PRE-OPERA TION SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. ------------------------------------------------------------------------ OIL This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil.
NOTES AAA-6 AAA-6 PIPELINER® 200G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
T ABLE OF CONTENTS - OPERA TION SECTION BBB-1 BBB-1 PIPELINER® 200G O p e r a t i o n ........................................................................... B B B - 1 S a f e t y P r e c a u t i o n s &D e s i g n S u m m a r y .............
OPERA TION BBB-2 BBB-2 SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturer ʼ s manual supplied with your welder . It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
OPERA TION BBB-3 BBB-3 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 are standard. Engine Hour Meter A meter to record the hours of operation.
OPERA TION BBB-4 BBB-4 PIPELINER® 200G CONTROL OF WELDING CURRENT DO NOT TURN THE “CURRENT RANGE SELEC- TOR” WHILE WELDING because the current may arc between the contacts and damage the switch. ------------------------------------------------------------------------ The “Current Range Selector” provides five overlap- ping current ranges.
T ABLE OF CONTENTS - ACCESSORIES SECTION CCC-1 CCC-1 A c c e s s o r i e s ......................................................................... C C C - 1 O p t i o n a l E q u i p m e n t& R e m o t e C o n t r o l s .........................
ACCESSORIES CCC-2 CCC-2 PIPELINER® 200G OPTIONAL EQUIPMENT (FIELD INST ALLED) (K704) Accessory Set Includes 35 ft (10.7m) electrode and 30 ft (9.1m) work cables, headshield, work clamp, and electrode holder . Pipe Thawing with an arc welder can cause fire, explosion, damage to electric wiring or to the arc welder if done improperly .
T ABLE OF CONTENTS - MAINTENANCE SECTION DDD-1 DDD-1 PIPELINER® 200G M a i n t e n a n c e ......................................................................... D D D - 1 S a f e t y P r e c a u t i o n s .........................................
MAINTENANCE DDD-2 DDD-2 PIPELINER® 200G SAFETY PRECAUTIONS GENERAL INSTRUCTIONS 1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation.
MAINTENANCE DDD-3 DDD-3 PIPELINER® 200G BEARINGS This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal service. Where the welder is used con- stantly or in excessively dirty locations, it may be nec- essary to add one-half ounce of grease per year .
MAINTENANCE DDD-4 DDD-4 PIPELINER® 200G I EVERY 600 HOURS OR 12 MONTHS E VERY 200 HOURS OR 6 MONTHS EVERY 100 HOURS OR 3 MONTHS FIRST SERVICE-(50 HOURS) E VERY DAY OR EVERY 8 HOURS If necessary use shorter periods. These preventive maintenance periods apply to average conditions of operation.
MAINTENANCE DDD-5 DDD-5 PIPELINER® 200G 9 8 1 5 2 7 9 4 6 3 6 Figure DDD.1 - Major Component Location 1. Case Front Assembly 2. Engine Assembly 3. Exciter Frame, Armature Assembly 4. Generator Frame, Armature & Coupling 5. Fuel T ank Assembly 6. Generator & Exciter Brush Holder Assemblies 7.
NOTES DDD-6 DDD-6 PIPELINER® 200G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Mast.
T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 PIPELINER® 200 T h e o r y o f O p e r a t i o n ..................................................................... E - 1 G e n e r a l D e s c r i p t i o n ................................
THEOR Y OF OPERA TION GENERAL DESCRIPTION The PIPELINER® 200 is a heavy duty , engine driven, DC arc welding power source capable of providing con- stant current output for stick welding or DC TIG weld- ing. Also, a total of 1750 watts of auxiliary power is available at the 120VDC receptacle.
THEOR Y OF OPERA TION E-3 E-3 PIPELINER® 200 BA TTER Y , ST ARTER, ENGINE AL TERNA TOR, OIL, & TEMPERA TURE SWITCH CIRCUITS The 12VDC battery powers the starter motor and, through the ignition switch, the engine ignition circuitry (gas models only), the engine alternator , the engine control protection modules and associated circuits.
THEOR Y OF OPERA TION E-4 E-4 PIPELINER® 200 BA TTER Y , ST ARTER, ENGINE AL TERNA TOR, OIL, & TEMPERA TURE SWITCH CIRCUITS The 12VDC battery powers the starter motor and, through the ignition switch, the engine ignition circuitry (gas models only), the engine alternator , the engine control protection modules and associated circuits.
THEOR Y OF OPERA TION E-5 E-5 PIPELINER® 200 BA TTER Y , ST ARTER, ENGINE AL TERNA TOR, OIL, & TEMPERA TURE SWITCH CIRCUITS The 12VDC battery powers the starter motor and, through the ignition switch, the engine ignition circuitry (gas models only), the engine alternator , the engine control protection modules and associated circuits.
THEOR Y OF OPERA TION E-6 E-6 PIPELINER® 200 ENGINE, MAIN GENERA TOR ARMA TURE & FRAME AND DC EXCITER EXCIT A TION (FLASHING) The main generator armature and the exciter armature are mechanically coupled to the engine.
THEOR Y OF OPERA TION E-7 E-7 PIPELINER® 200 DC GENERA TOR MACHINES The armature winding of a DC generator is located on the rotating member . Current is conducted from it by means of carbon brushes. The field winding is located in the stator , which is stationary and excited by direct current.
NOTES E-8 E-8 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO.
T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR F-1 F-1 PIPELINER® 200 T r o u b l e s h o o t i n g a n d R e p a i r .............................................................. F - 1 H o w t o U s eT r o u b l e s h o o t i n g G u i d e ....
TROUBLESHOOTING & REP AIR F-2 F-2 PIPELINER® 200 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPT OM). Look under the column labeled “PROBLEM (SYMPTOMS)”.
TROUBLESHOOTING & REP AIR F-3 F-3 PIPELINER® 200 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not un.
TROUBLESHOOTING & REP AIR F-11 F-11 PIPELINER® 200 Observe all Safety Guidelines detailed throughout this manual LIGHT CODE F AILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE LONG 1, SHORT 1 R.
NOTES F-12 F-12 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
DC EXCITER TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-14 F-14 PIPELINER® 200 SERIES COIL CONNECTION POINT (NEGA TIVE) POSITIVE FIGURE F .1 – 120VDC RECEPT ACLE TEST PROCEDURE 1. T urn off the engine and remove all external loads to the welder terminals and auxiliary receptacle.
DC EXCITER TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-15 F-15 PIPELINER® 200 EXITER COVER W ARRANTY CHECK VOLTAGE A T BRUSH HOLDERS HERE (RIGHT SIDE IS +) + FIGURE F .2 – EXCITER COVER REMOVAL 4. T urn off the engine. Using the 3/8” nut driver , remove the exciter cover .
TROUBLESHOOTING & REP AIR F-16 F-16 PIPELINER® 200 WHITE FLEX LEAD SMALL FLEX LEAD SOLID LEAD WARRANTY FIGURE F .3 – BRUSH HOLDER LEADS SHUNT COIL AND SERIES COIL RESIST ANCE TESTS 7. T urn the engine OFF . 8. Using the 3/8" nut driver , disconnect the two leads from the left side brush holder .
TROUBLESHOOTING & REP AIR F-17 F-17 PIPELINER® 200 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-18 F-18 PIPELINER® 200 IDLER SOLENOID TEST (continued) FIGURE F .4 – IDLER SOLENOID CONNECTIONS QUICK CONNECT LEADS TEST PROCEDURE 1. T urn the engine OFF . 2. Unlatch and secure the right side door . 3. Locate the idler solenoid and the two leads with quick connects.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-20 F-20 PIPELINER® 200 MAIN GENERA T OR SHUNT FIELD WINDING TEST (continued) FIGURE F .5 – PLUG P10 LOCA TION PLUG P10 TEST PROCEDURE 1. T urn the engine OFF . 2. Unlatch, lift and secure the right side door . 3. Locate plug P10.
TROUBLESHOOTING & REP AIR F-21 F-21 PIPELINER® 200 MAIN GENERA T OR SHUNT FIELD WINDING TEST (continued) FIGURE F .6 – PLUG P10 PIN ASSIGNMENTS PIN 3 PIN 5 TA B 5. Locate the blue (U) (pin 3) and the brown (N) (pin 5) leads in the harness plug.
NOTES F-22 F-22 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
TROUBLESHOOTING & REP AIR F-24 F-24 PIPELINER® 200 FLASHING THE FIELDS (continued) FIGURE F .7 – EXCITER COVER REMOV AL EXITER COVER PROCEDURE 1.
TROUBLESHOOTING & REP AIR F-25 F-25 PIPELINER® 200 FLASHING THE FIELDS (continued) FIGURE F .8 - BRUSH HOLDER/BA TTER Y JUMPER CONNECTIONS + RAISE EXCITER BRUSH OFF COMMUT AT OR TO POSITIVE BA TTERY TERMINAL TO NEGATIVE BA TTERY TERMINAL WARRANTY 3.
NOTES F-26 F-26 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
ENGINE AL TERNA TOR TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-28 F-28 PIPELINER® 200 Alternator Output Leads BACK OF AL TERNA TOR FIGURE F .9 - AL TERNA TOR LEAD LOCA TIONS TEST PROCEDURE 1. T urn the engine off. 2. Open the engine access door and check the voltage at the battery terminals.
OIL PRESSURE - TEMPERA TURE SWITCH TEST W ARNING TROUBLESHOOTING & REP AIR F-29 F-29 PIPELINER® 200 Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
G WK OIL SWITCH / SENDER S17026-3 TEMP SW . / SENDER S25162 1 /2-14 NPT 1/4" SP ADE TERMINAL 3/16" SP ADE TERMINAL G W G ND .19 .03 + - FIGURE F .10 - SWITCH WK TERMINAL TO GROUND TO CASE A T 6 +/-2 PSI. OTHERWISE TERMINAL TO BE OPEN OIL PRESSURE - TEMPERA TURE SWITCH TEST (CONTINUED) PROCEDURE 1.
TROUBLESHOOTING & REP AIR F-31 F-31 PIPELINER® 200 OIL PRESSURE - TEMPERA TURE SWITCH TEST (CONTINUED) PROCEDURE 1. With the engine not running, and at room temperature, locate the T emperature Switch/Sender . 2. Remove the two leads from the switch.
NOTES F-32 F-32 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
B OL T / NUT (4) “ L ” DOOR H OOKS (4) FIGURE F .1 1 - CASE COVERS CURRENT SENSOR PCB TEST (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Remove the four nuts and bolts holding the case top and doors assembly to the welder frame. See Figure F .
FIGURE F .12 - CURRENT SENSING PCB CURRENT SENSOR PCB TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-35 F-35 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return .
NOTES F-36 F-36 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
BLOWER P ADDLE MARK FIGURE F .13 - BLOWER P ADDLE MARK LOCA TION ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) (PERKINS ONL Y) PROCEDURE Strobe T ach Method 1. T urn the engine off. 2. Unlatch, lift and secure the right side door . Note: Latches are located at both ends of the door .
ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) (PERKINS ONL Y) PROCEDURE 6. If either of the readings is incorrect, adjust the throt- tle as follows: Adjust HIGH IDLE: The Engine is Preset at factory . Contact Perkins @ 1-888-737-5364 or www .perkins.com Adjust LOW IDLE: First make sure there is no load on the machine.
IDLER ROD IDLER ADJUSTMENT L OCK NUT BALL JOINT FIGURE F .14 – SOLENOID LOCA TION ENGINE THROTTLE ADJUSTMENT TEST (CONTINUED) (PERKINS ONL Y) TROUBLESHOOTING & REP AIR F-40 F-40 PIPELINER® 200 .
TROUBLESHOOTING & REP AIR F-41 F-41 PIPELINER® 200 This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time.
TROUBLESHOOTING & REP AIR F-42 F-42 PIPELINER® 200 This is the typical DC welding output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
TROUBLESHOOTING & REP AIR F-43 F-43 PIPELINER® 200 This is the typical DC welding output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
NOTES F-44 F-44 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
DC EXCITER ARMA TURE & FIELD COILS REMOV AL AND REPLACEMENT PROCEDURE TROUBLESHOOTING & REP AIR F-46 F-46 PIPELINER® 200 FIGURE F .15 – EXCITER COVER REMOV AL ARMA TURE BRUSH HOLDER ASSEMBL.
DC EXCITER ARMA TURE & FIELD COILS REMOV AL AND REPLACEMENT PROCEDURE TROUBLESHOOTING & REP AIR F-47 F-47 PIPELINER® 200 Field Coils Removal Procedure 1. Perform the DC Exciter Armature Removal Procedure. 2. Using the 3/8” wrench, remove the leads from the brush holder .
NOTES F-48 F-48 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE W ARNING TROUBLESHOOTING & REP AIR F-49 F-49 PIPELINER® 200 Service and repair should be performed by only Lincoln Electric factory trained personnel.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-50 F-50 PIPELINER® 200 FIGURE F .16 – BA TTERY P ANEL REMOV AL NEGA TIVE BA TTER Y CABLE PROCEDURE 1. T urn the engine OFF . 2. Using the 7/16” wrench, remove the two bolts and washers and partially slide out the battery mounting panel.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-51 F-51 PIPELINER® 200 FIGURE F .17 – TOP AND DOORS ASSEMBL Y DET AILS BOL T / NUT (4) 'L' DOOR HOOKS (4) 4. Using the 1/2” wrench, remove the four nuts and bolts holding the case top and doors assembly to the welder frame.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-52 F-52 PIPELINER® 200 FIGURE F .18 – FUEL T ANK MOUNTING DET AILS BOL TS / NUTS / W ASHERS (4) FUEL T ANK FUEL BOWL RAILS FUEL LINE 5. Perform the DC Exciter Armature Removal Procedure.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-53 F-53 PIPELINER® 200 FIGURE F .19 – SELECTOR SWITCH LEAD REMOVAL SELECTOR SWITCH TERMINAL LEAD (5) A C B D E 9. Using the 1/2” wrench, remove the five heavy flex leads from the selector switch terminals.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-54 F-54 PIPELINER® 200 FIGURE F .21 – CHOKE CONTROL CABLE REMOVAL LOOSEN HERE CHOKE CABLE 12. Using the slot head screw driver , remove the choke control cable from the engine carbure- tor assembly .
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-55 F-55 PIPELINER® 200 FIGURE F .22 – FRONT P ANEL WIRING CONNECTIONS A C B D E IDLER SWIT CH LEADS T O AMMETER DC RECEPT ACLE IDLER PC BOARD T O IDLER SWIT CH IGNITION SWIT CH ST ART BUT T ON SHUNT LEADS QUICK DISC ONNECT 13.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-56 F-56 PIPELINER® 200 FIGURE F .23 – FRONT P ANEL F ASTENER REMOV AL BOL TS / NUTS / W ASHERS (2) BASE MOUNTING BOL TS (4) MIDDLE SCREW (1) 23.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-57 F-57 PIPELINER® 200 FIGURE F .24 – BRUSH BRACKET WRAP-AROUND COVER BRUSH BRACKET WRAP- AROUND COVER REMOVE (2) NUTS, W ASHERS, AND SCREWS 27.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-58 F-58 PIPELINER® 200 FIGURE F .26 – MAIN GENERA TOR FEET MOUNTING MAIN GENERA TOR REMOVE MOUNTING NUTS, WASHERS, AND BOL TS FEET (2) 30.
MAIN GENERA T OR FRAME REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-59 F-59 PIPELINER® 200 33. Using the rope sling and pry bars, carefully lift and “wiggle” the generator frame away from the engine and armature assembly .
NOTES F-60 F-60 PIPELINER® 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
MAIN GENERA TOR ARMA TURE REMOV AL AND REPLACEMENT PROCEDURE TROUBLESHOOTING & REP AIR F-62 F-62 PIPELINER® 200 FIGURE F .28 – MAIN GENERA TOR ARMA TURE MOUNTING MOUNTING BOL TS / LOCK W ASHERS (8) BLOWER P ADDLE SLING PROCEDURE 1. T urn the engine OFF .
TROUBLESHOOTING & REP AIR F-63 F-63 PIPELINER® 200 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could af fect the machineʼs electrical characteristics.
NOTES F-64 F-64 PIPELINER 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO.
T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 PIPELINER 200 E l e c t r i c a l D i a g r a m s ..................................................................... G - 1 W i r i n g D i a g r a m -C o d e 1 0 6 6 0 - ( L 1 1 4 0 2 ) .................
ELECTRICAL DIAGRAMS G-2 PIPELINER® 200 WIRING DIAGRAM - CODE 10660 - (L1 1402) A 54 3 2 1 NEGATIVE SELECTOR SWITCH WELDER LEAD BLOCK 42 602A U 1 2 3 4 5 6 600A 41 G ENERA TO R N 600B 6 10 602B J5 P9 J8 POSITIVE P 10 N U RHEOSTAT (CC -) (CC+ ) & ( CV+ WITH W.
ELECTRICAL DIAGRAMS G-3 PIPELINER® 200 WIRING DIAGRAM - CODE 10913, 1 1136 - (L1 1864) L11864 PIPEL I NER 200 G WIRI NG DI AGRAM B A 54 3 2 1 NEGA TI VE SELECTOR SW IT CH WELDER LEAD BLOCK 42 602A U 1 2 3 4 5 6 600A 41 GEN ERATOR N 600B 610 602B J5 J8 POS ITI VE P10 N U R HEOSTAT (CC -) (CC+ ) & ( CV+ W IT HW .
ELECTRICAL DIAGRAMS G-4 PIPELINER® 200 WIRING DIAGRAM - CODE 10929 - (M20056) 761 F1 15A 840 B PIPELI NER 200 D WIRING DI AGRAM M20056 START + 52 + - - 51 56 EXC + PUMP SO LENOID 50 50B S B + R 1 2 3.
ELECTRICAL DIAGRAMS G-5 PIPELINER® 200 WIRING DIAGRAM - CODE 1 11 14, 11316 - (M20464) S B W IRE FEED MOD ULE (OPT IONAL) 608 609 + PIPELI NER 200D WIRIN G DIAGRA M A M2 0464 PLUG P5 INLINE CONNECTO RS W.F.M . CONTROL PANEL CONNECT TO POS. & NEG.
ELECTRICAL DIAGRAMS G-6 PIPELINER® 200 WIRING DIAGRAM - CODE 1 1471 - (M21564) S B W IRE FEED M ODULE ( OP TI ONA L) 608 609 + PIPELINER 200 D WIRING DIA GRA M B M2 1564 PRINT PLUG P5 INLINE CONNE CTORS W.F.M. CONTROL PANEL CONNECT TO POS. & NEG.
ELECTRICAL DIAGRAMS G-7 PIPELINER® 200 SCHEMA TIC -COMPLETE MACHINE - CODE 10929 - (L12020) L12020 PIPELINER 200D MACHINE SCHEMATIC NA L11946 JRS JRS UN LE SS OTHERWI SE SPE CIFIED TO LE RANCE M ANU F AC TURING T OL ER ANC E P ER E 2056 ON 2 PLACE DE CI MALS IS ± .
ELECTRICAL DIAGRAMS G-8 PIPELINER® 200 SCHEMA TIC - COMPLETE MACHINE - CODE 11 1 14, 11316 - (L12362) L12362 PIPELI NER 200 D ( KUBOTA V22 03M) MACHINE SCHEMATIC NA L12020 DM J. STAPP UN LE SS OTHERWI SE SPE CIFIED TO LE RANCE M ANU F AC TURING T OL ER ANC E P ER E 2056 ON 2 PLACE DE CI MALS IS ± .
ELECTRICAL DIAGRAMS G-9 PIPELINER® 200 SCHEMA TIC - COMPLETE MACHINE - CODE 11471 - (L13350) L13350 PIP EL INE R 200 D K UBOTA MA C HI NE SC HE MATI C NONE L12362 DO NOT SCAL E T HIS DR A WING EQU IP.
ELECTRICAL DIAGRAMS G-10 PIPELINER® 200 SCHEMA TIC - CURRENT SENSE PC BOARD - CODE 10929,11 1 14, 11316, 1 1471 - (S25973) S25973 CLASSI C SERI ES CURRENT SEN SE PC BOARD SCHEMAT IC NONE - BTV DM U NLESS OT HERWI SE SPE C IF IED T OLE RANCE MAN UFA CT URING TOLE RA N CE PER E2056 ON 2 PLACE DEC I MALS IS ± .
ELECTRICAL DIAGRAMS G-11 PIPELINER® 200 SCHEMA TIC - IDLER/ENGINE SHUTDOWN - CODE 10929 (L10826) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
Un point important après l'achat de l'appareil (ou même avant l'achat) est de lire le manuel d'utilisation. Nous devons le faire pour quelques raisons simples:
Si vous n'avez pas encore acheté Lincoln Electric PIPELINER 200 c'est un bon moment pour vous familiariser avec les données de base sur le produit. Consulter d'abord les pages initiales du manuel d'utilisation, que vous trouverez ci-dessus. Vous devriez y trouver les données techniques les plus importants du Lincoln Electric PIPELINER 200 - de cette manière, vous pouvez vérifier si l'équipement répond à vos besoins. Explorant les pages suivantes du manuel d'utilisation Lincoln Electric PIPELINER 200, vous apprendrez toutes les caractéristiques du produit et des informations sur son fonctionnement. Les informations sur le Lincoln Electric PIPELINER 200 va certainement vous aider à prendre une décision concernant l'achat.
Dans une situation où vous avez déjà le Lincoln Electric PIPELINER 200, mais vous avez pas encore lu le manuel d'utilisation, vous devez le faire pour les raisons décrites ci-dessus,. Vous saurez alors si vous avez correctement utilisé les fonctions disponibles, et si vous avez commis des erreurs qui peuvent réduire la durée de vie du Lincoln Electric PIPELINER 200.
Cependant, l'un des rôles les plus importants pour l'utilisateur joués par les manuels d'utilisateur est d'aider à résoudre les problèmes concernant le Lincoln Electric PIPELINER 200. Presque toujours, vous y trouverez Troubleshooting, soit les pannes et les défaillances les plus fréquentes de l'apparei Lincoln Electric PIPELINER 200 ainsi que les instructions sur la façon de les résoudre. Même si vous ne parvenez pas à résoudre le problème, le manuel d‘utilisation va vous montrer le chemin d'une nouvelle procédure – le contact avec le centre de service à la clientèle ou le service le plus proche.
