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PROCEDURE (continued)
Initial rocker placement:
1.The rocker should be initially positioned so the center of brushes visually lines up with the center of the main poles. Lining up the four brush holder studs with the four exciter brack- et mounting bolts is acceptable for initial place- ment. The rocker should be tight against the shoulder of the hub and the clamping screw should be tightened only enough to assure the rocker cannot move.
IMPORTANT: DO NOT OVER TIGHTEN. Over tightening the rocker clamp screw can destroy the rocker.
2.Check that the brush holders are properly installed and positioned correctly. See the
Welding generator Brush and Commutator Inspection and Service Procedure.
3.Start the engine, place the idle switch in the high idle position, and seat the brushes using a commutator stone. See the Welding gener- ator Brush and Commutator Inspection and Service Procedure.
4.Use a load bank to apply a 100% duty cycle load (400 amps @ 36 volts). Look at the brushes while the load is applied. If excessive sparking is observed, adjust the rocker position to minimize sparking. Generally, moving the rocker slightly in the direction of the armature rotation will reduce sparking.
5.Continue running the machine under load for at least 30 minutes to bring the machine up to normal operating temperature and to fully seat the brushes.
Check for Max output.
6.Remove the load, set the output control and rheostat to maximum,
WARNING: Do not move the Current Control while the machine is under load.
7.Measure the output voltage, it should read between 45 and 51 Volts DC
8.Measure the engine RPM, it should measure between 1680 and 1795 RPM.
If the engine RPM is not within specification, Perform the Engine RPM Adjustment Test, if the engine high idle RPM is normal, but the load RPM is significantly less than specified above, the engine or governor may be malfunctioning. See the engine troubleshooting procedures in this man- ual and/or have the engine serviced or repaired by a qualified engine technician.
If the weld output voltage is lower than specified above, the rocker position will need to be adjusted. Generally, moving the rocker opposite the arma- ture rotation direction will increase output voltage. When making this adjustment, the rocker should only be moved in very small increments. The adjustment may need to be repeated several times to achieve the desired result.
9.Remove the load and check the voltage at the output studs (OCV). The voltage should mea- sure 93 to 99 Volts DC.
After the rocker has been adjusted and the machine is operating normally, the rocker locking screw should be tightened to
If new parts had been installed, the new rocker and/or exciter bracket location should be marked with a 1/8” drill mark. See Figure F.18.
