Lincoln Electric 200 service manual Bearings Idle Control Maintenance, DDD-3

PIPELINER® 200G

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DDD-3			MAINTENANCE			DDD-3
BEARINGS					IDLE CONTROL 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-
stantly or in excessively dirty locations, it may be nec-					circuit board, disconnect the battery.
essary to add one-half ounce of grease per year. A pad					------------------------------------------------------------------------
of grease one inch wide, one inch long, and one inch					1. Proper operation of the idler requires good ground-
high weighs approximately one-half ounce. Over-
greasing is far worse than insufficient greasing.					ing of the battery and TBI controller.
When greasing the bearings, keep all dirt out of the					2. If desired, the welder can be used without automat-
area. Wipe the fittings completely clean and use clean					ic idling by setting the “Idler” switch to the “High
equipment. More bearing failures are caused by dirt					Idle” position.
introduced during greasing than from insufficient					3. When installing a new battery or using a jumper
grease.
COMMUTATOR AND BRUSHES					battery to start the engine, be sure the	battery
					is negative ground. Damage to the engine alterna-
					polarity is connected properly. The correct polarity
		WARNING			tor and the TBI controller board can result from
					incorrect connection.
U	ncovered rotating equipment can be dangerou			s.	NAMEPLATES
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself					Whenever routine maintenance is performed on this
from particles that may be thrown out by the rotat-
ing armature when stoning the commutator.					machine - - or at least yearly - - inspect all nameplates
------------------------------------------------------------------------					and labels for legibility. Replace those which are no
The generator brushes are properly adjusted when the					longer clear. Refer to the parts list for the replacement
welder is shipped. They require no particular attention.					item number.
DO NOT SHIFT THE BRUSHES or adjust the rocker					PURGING AIR FROM FUEL SYSTEM
setting. Shifting of the brushes may result in:
	• Change in machine output				The fuel system operates as follows: The fuel pump
	•	Commutator damage			will operate for a maximum of 3 seconds when the igni-
	•	Excessive brush wear			tion switch is turned “ON”. The pump will restart once
Periodically inspect the commutator and brushes by					the start button is pushed and continue when the
					engine starts. To purge the system of air if fuel lines
removing the covers. DO NOT remove or replace					have been removed, the ignition switch can be toggled
these covers while the machine is running.					“ON” and “OFF” (at 3 second intervals) until fuel flows
Commutators require little attention. However, if they					through the fuel return line in the neck of the fuel line.
are black or appear uneven, have them cleaned by an
experienced maintenance man using fine sandpaper
or a commutator stone. Never use emery cloth or
paper for this purpose.

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.