MAINTENANCE
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WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the Classic II in clean, dry, protect- ed areas.
CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas.
ALTERNATOR BRUSH REMOVAL AND REPLACE- MENT: It's normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary. Remove the brushes and clean the slip rings with fine emery paper. To seat new slip ring brushes, position the brushes in place. Then slide one end of a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes. With slight additional finger pres- sure on top of the brushes, pull the sandpaper around the circumference of the rings - in the direction of rota- tion only - until brushes seat property. Brushes must be seated 100%.
COMMUTATOR AND BRUSHES: The generator brushes are properly adjusted when the welder is shipped. They require no particular attention.
CAUTION
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
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 experienced maintenance personnel 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.
Arcing or excessive exciter brush wear indicates a pos- sible misaligned shaft. Have an authorized Lincoln Electric Field Service facility check and realign the shaft.
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 rotating armature when stoning the commutator.
CURRENT RANGE SELECTOR CONTACTS: The contacts should not be greased. To keep the contacts clean, rotate the current control handle through its entire range frequently. Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld.
Put a drop of oil on the CURRENT RANGE SELEC- TOR shaft at least once every month.
RECEPTACLES: Keep the electrical receptacles in good condition. Remove any dirt, oil, or other debris from their surfaces and holes.
CABLE CONNECTIONS: Check the welding cable connections at the weld output terminals often. Be sure that the connections are always firm.
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Periodically inspect the commutator, slip rings, and brushes by removing the covers. DO NOT remove these covers while the machine is running.
Commutators and brushes require little attention. However, if they are black or appear uneven, have them cleaned by experienced maintenance personnel using a commutator stone. Never use emery cloth or paper for this purpose.
IDLER MAINTENANCE
1.The solenoid plunger must work freely and not bind. Dust the plunger about once a year with graphite powder.
2.Proper operation of the idler requires good ground- ing of the PC board, reed switch, and battery.
3.If desired, the welder can be used without automatic idling by setting the IDLER switch to the “HIGH” position.
