Welder/Generator Maintenance; Commutator And Brushes; Cable Connections; Idler Maintenance - Lincoln Electric CLASSICII SVM125-A Service Manual

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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:

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
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.
MAINTENANCE
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.
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
The generator
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.

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.
CLASSIC II
WARNING
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