Maintenance, Warning caution – Lincoln Electric PIPELINER 200 User Manual

Page 41

MAINTENANCE

DD-3

PIPELINER® 200D PERKINS

BEARINGS

This welder is equipped with a double-shielded ball

bearing having sufficient grease to last indefinitely

under normal service. Where the welder is used con-

stantly or in excessively dirty locations, it may be nec-

essary 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 BRUSHES

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.

------------------------------------------------------------------------

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 and brushes by

removing the covers. DO NOT remove or replace

these covers while the machine is running.

Commutators 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.

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.

IDLER MAINTENANCE

Before doing electrical work on the idler printed

circuit board, disconnect the battery.

------------------------------------------------------------------------

When installing a new battery or using a jumper battery

to start the engine, be sure the battery polarity is con-

nected properly. The correct polarity is negative

ground. Damage to the engine alternator and the print-

ed circuit board can result from incorrect connection.

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 printed circuit board, current sensor and

battery.

3. Idler solenoid is activated for high idle.

4. If desired, the welder can be used without automat-

ic idling by setting the “Idler” switch to the “High”

position.

NAMEPLATES

Whenever routine maintenance is performed on this

machine - or at least yearly - inspect all nameplates

and labels for legibility. Replace those which are no

longer clear. Refer to the parts list for the replacement

item number.

PURGING AIR from FUEL SYSTEM

(Perkins 104.22 Engine)

Keep fuel clear of open flames or arcs, allow

engine to cool before working on the fuel system.

Wipe up any spilled fuel and do not start engine

until fumes clear.

------------------------------------------------------------------------

If the engine is running rough and you suspect air has

been trapped in the fuel system, (EG. the engine was

allowed to run out of fuel) perform the following steps

using qualified personnel:

WARNING

CAUTION