Lincoln Electric IM870-A Bearing Maintenance, Commutator and Brush Maintenance, Cooling System

D-2 MAINTENANCE D-2

BEARING MAINTENANCE

This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal ser- vice. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one-half ounce of grease per year. A pad of grease one inch wide, one inch long and one inch high weighs approximately one-half ounce. Over greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of the area. Wipe the fittings completely clean and use clean equipment. More bearing failures are caused by dirt introduced during greasing than from insufficient grease.

COMMUTATOR AND BRUSH MAINTENANCE

WARNING

Uncovered rotating equipment can be dangerous. Use care so your hands, hair, clothing or tools do not catch in the rotating parts. Protect yourself from particles that may be thrown out by the rotat- ing armature when stoning the commutator.

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The generator brushes are properly adjusted when the welder is shipped. They require no particular attention. DO NOT SHIFT THE BRUSHES or adjust the rocker setting.

Shifting of the brushes may result in:

-Change in machine output

-Commutator Damage

-Excessive brush wear

Periodically inspect the commutator, slip rings and brushes by removing the covers. DO NOT remove or replace these covers while the machine is running.

Commutators and slip rings require little attention. However, if they 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.

NOTE: If the welder is used in dirty or dusty locations, or if the welder is not used for prolonged periods of time, it may be necessary to clean the commutator and slip rings more often.

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

To seat the slip ring brushes, position the brushes in place. Then slide one end of a piece of fine sandpa- per between slip rings and brushes with the coarse side against the brushes. Pull the sandpaper around the circumference of the rings, in direction of rotation only - until brushes seat properly. In addition, stone slip ring with a fine stone. Brushes must be seated 100%.

Arcing or excessive exciter brush wear indicates a possible misaligned shaft. Have an authorized Field Service Shop check and realign the shaft.

COOLING SYSTEM

The SAE-400 SEVERE DUTY is equipped with a pressure radiator. Keep the radiator cap tight to pre- vent loss of coolant. Clean and flush the cooling sys- tem periodically to prevent clogging the passage and overheating the engine. When antifreeze is needed, always use the permanent type.

WARNING

FUEL FILTERS

When working on the fuel system

•Keep ungrounded lights away, do not smoke !

•Do not spill fuel !

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The SAE-400 SEVERE DUTY is equipped with a Fuel Pre-Filter/Water Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors. The Fuel Pre-Filter/Water Separator is mounted to the engine block just below the lift pump.

The Secondary Fuel Filter is mounted directly to the engine just above the oil filter.

FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY

The pre-filter is a 150 micron screen designed to pro- tect against gross fuel contamination of the water sep- arator element and the Secondary Fuel Filter. If the pre-filter becomes plugged it may be removed, inspected, cleaned and reinstalled. In general this only needs to be done with each water separator ele- ment change (about every 1,000 hrs.) However if at any time excessive fuel contamination is suspected or

asudden fall-off in engine performance is detected the pre-filter screen should be inspected and cleaned. Follow the following procedure:

SAE-400 SEVERE DUTY