Lincoln Electric 200 service manual Bearings Idler Maintenance, Commutator and Brushes

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DD-3			MAINTENANCE				DD-3
BEARINGS					IDLER MAINTENANCE
This welder is equipped with a double-shielded ball						CAUTION
bearing having sufficient grease to last indefinitely					Before doing electrical work on the idler printed
under normal service. Where the welder is used con-					circuit board, disconnect the battery.
stantly or in excessively dirty locations, it may be nec-					------------------------------------------------------------------------
essary to add one-half ounce of grease per year. A pad					When installing a new battery or using a jumper battery
of grease one inch wide, one inch long, and one inch					to start the engine, be sure the battery polarity is con-
high		weighs approximately one-half ounce. Over-			nected properly. The correct polarity is		negative
greasing is far worse than insufficient greasing.					ground. Damage to the engine alternator and the print-
When greasing the bearings, keep all dirt out of the					ed circuit board can result from incorrect connection.
area. Wipe the fittings completely clean and use clean					1. The solenoid plunger must work freely and not bind.
equipment. More bearing failures are caused by dirt						Dust the plunger about once a year with graphite
introduced during greasing than from insufficient					2.	powder.
grease.						Proper operation of the idler requires good ground-
COMMUTATOR AND BRUSHES						ing of the printed circuit board, current sensor and
						battery.
		WARNING			3.	Idler solenoid is activated for high idle.
Un	covered rotating equipment can be dangerou			s.	4. If desired, the welder can be used without automat-
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself						ic idling by setting the “Idler” switch to the “High”
from particles that may be thrown out by the rotat-						position.
ing armature when stoning the commutator.					NAMEPLATES
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The generator brushes are properly adjusted when the					Whenever routine maintenance is performed on this
welder is shipped. They require no particular attention.
DO NOT SHIFT THE BRUSHES or adjust the rocker					machine - or at least yearly - inspect all nameplates
setting. Shifting of the brushes may result in:					and labels for legibility. Replace those which are no
	• Change in machine output				longer clear. Refer to the parts list for the replacement
					item number.
	•	Commutator damage			PURGING AIR from FUEL SYSTEM
	•	Excessive brush wear
Periodically inspect the commutator and brushes by					(Perkins 104.22 Engine)
					Keep fuel clear of open flames or arcs, allow
removing the covers. DO NOT remove or replace					engine to cool before working on the fuel system.
these covers while the machine is running.					Wipe up any spilled fuel and do not start engine
Commutators require little attention. However, if they					until fumes clear.
					------------------------------------------------------------------------
are black or appear uneven, have them cleaned by an					If the engine is running rough and you suspect air has
experienced maintenance man using fine sandpaper					been trapped in the fuel system, (EG. the engine was
or a commutator stone. Never use emery cloth or					allowed to run out of fuel) perform the following steps
paper for this purpose.					using qualified personnel:
Replace brushes when they wear within 1/4” of the pig-
tail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face to fit
the commutator. Have an experienced maintenance
man seat these brushes by lightly stoning the commu-
tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston-
ing, blow out the dust with low pressure air.

Arcing or excessive exciter brush wear indicates a pos- sible misaligned shaft. Have an authorized Field

Service Shop check and realign the shaft.PIPELINER® 200D PERKINS