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Lincoln Electric SVM208-A Portable Generator User Manual

1. f i 0 olg 5 2 amp Return to Section TOC Return to Master TOC BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 38 TROUBLESHOOTING AND REPAIR CAPACITOR AND OR DIODE BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 12 LOCATION AND DISCHARGING THE FIELD CAPACITOR Attachment for 202 202A Cable Tie Capacitor PROCEDURE CAPACITOR REMOVAL AND REPLACEMENT 1 Remove the engine spark plug wire 2 With the 3 8 nut driver remove the 4 sheet metal screws that hold the top cover to the con trol box Remove the top cover Discharge the field capacitor by connecting the jumper wire clips on the black and the red wire terminals on the top of the capacitor See Figure F 12 for location Leave the clips on for at least 5 seconds then remove Both the capacitor and the diode bridge are mounted in a molded plastic holder To remove it pull out on the top of the holder then slide it upward Attachment for 201 201A Jumper 5 Snap the capacitor out of the assembly 6 Loosen the two screws on the top of the capac itor Lead 202A Red attaches to the positive terminal Leads 201 and 201A both Blac
2. DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 Oo cre 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC 41 TROUBLESHOOTING REPAIR F 41 STATOR ROTOR REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the Stator and or Rotor for maintenance or replacement of either component MATERIALS NEEDED Lincoln Electric Rotor Removal Kit S20925 FOR ROTOR REMOVAL ONLY 5 16 Nutdriver 1 2 Socket Wrench 6 Socket Extension Slot Head Screw Driver 5 8 Socket Wrench 7 16 Socket Wre
3. cre 5 5 Dllo amp c Return to Section TOC Return to Master TOC SAFETY PRECAUTIONS A WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machine Remove guards only when necessary to per form maintenance and replace them when the maintenance requiring their removal is com plete If guards are missing from the machine get replacements from a Lincoln Distributor See the EXPLODED VIEW AND PARTS LIST at the back of this manual Read the Safety Precautions in the front of this man ual and in the engine owner s manual before working on the Bulldog 140 Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the recoil housing fans and all other moving parts when start ing operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting disconnect the spark plug lead before servicing the engine See the engine owner s manual for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More frequent service may be required depending on your specific application and operating conditions Table D 1 shows engine main tenance replacement par
4. F 35 Capacitor And Or Diode Bridge Removal and Replacement F 37 Stator Rotor Removal and Replacement F 41 Retest and 5 estre tipiena F 49 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO gt 2 0 olg 1 5 2 amp Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems engine prob lems and welding problems Step 2
5. B 3 WELD ELECTRODE OUTPUT TERMINAL Pro vides the connection point for the electrode holder cable WELD WORK OUTPUT TERMINAL Provides the connection point for the work cable GROUND STUD Provides a connection point for connecting the machine case to earth ground 240 VOLT RECEPTACLE Connection point for sup 240 Volt power to operate one electrical device 120 VOLT DUPLEX RECEPTACLES 2 Connection point for supplying 120 Volt power HOUR METER Records the time that the engine has run for maintenance purposes OUTPUT PANEL CONTROLS FIGURE B 1 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio gt 2 Of c 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC B4 OPERATION B4 GASOLINE ENGINE CONTROLS Refer to your engine manual for the location of the fol lowing features 1 FUEL SHUTOFF VALVE Stops the flow of gaso line from the fuel tank to the carburetor Should be closed whenever you are finished using the Bulldog amp 140 Must be opened before you start the engine 2 FUEL TANK AND CAP See TECHNICAL SPECI FICATIONS for capacity NOTE you use any other alternate fuel tank or supply be sure to use a recommended in line fuel filter 3 MUFFLER
6. BULLDOG 140 LINCOLN B oa TROUBLESHOOTING AND REPAIR 8 ROTOR FLASHING CIRCUIT TEST continued A WARNING MOVING PARTS can injure Return to Section TOC Return to Master TOC Keep away from moving parts AX ENGINE EXHAUST can kill Use in open well ventilated areas or 23 vent exhaust to the outside M 5 Start the engine and run it at High Idle 3700 3800 RPM 6 The DC ammeter should read between 0 15 and 0 30 amps Return to Section TOC Return to Master TOC 7 If the DC ammeter reads 0 0 amps check for flashing voltage between lead 202 from the brush holder and case ground lead 201 See Figure 4 the Wiring Diagram Normal flashing voltage is 2 05 VDC 8 If normal flashing voltage is present perform the Rotor Resistance Test Also be sure that all 201 leads have continuity zero ohms to case ground 9 If flashing voltage is not measured check from lead 205 on the diode bridge D3 to case ground Normal readings are around 3 VAC If no flashing voltage is present the engine mag neto may be faulty Check lead 205 back to magneto and measure for voltage there 10 If there is AC volts at the diode bridge the diode may be open Check diode and move leads over if need be eio E f i 0 c 5 5 Dllo amp c Return to Section TOC Return to Master TOC BULLDOG 140 LINCOLN B F 20
7. e Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or 23 vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or service this equipment LOCATION AND VENTILATION Whenever you use the Bulldog 140 be sure that clean cooling air can flow through the machine s gaso line engine and the generator Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the back end of the generator anywhere near hot engine exhaust from another machine And of course make sure that engine exhaust is ventilated to an open outside area The Bulldog 140 must be used outdoors Do not set the machine in puddles or otherwise submerge it in water Such practices pose safety hazards and cause improper operation and corrosion of parts Always operate the Bulldog 140 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices STORING 1 Store the machine in a cool dry place when it s not in use Protect it from dust and dirt Keep it where
8. Certain electrical devices cannot be powered by the Bulldog 140 Refer to Table A 2 for these devices CIRCUIT BREAKERS Auxiliary power is protected by circuit breakers When the machine is operated in high temperature environ ments the breakers may tend to trip at lower loads than normally CAUTION Never bypass the circuit breakers Without over load protection the Bulldog 140 could overheat and or cause damage to the equipment being used Return to Section TOC Return to Master TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC BULLDOG 140 LINCOLN B INSTALLATION Return to Section TOC Return to Master TOC Return to Section TOC eio OJO gt 2 0 Of dc 9 gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION CAUTION Certain Electrical devices cannot be powered by the Bulldog 140 See Table 2 TABLE A 2 ELECTRICAL DEVICE USE WITH THE Bulldog 140 Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent NONE light bulbs electric range hot pan skillet coffee maker Capacitive TV sets radios microwaves Voltage spikes or high voltage appliances with electrical control regulation can cause the capaci tative elements to fail Surge pro
9. F 24 DOL 19159 01 DOL 01 DOL 01 DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 olg 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC F 25 TROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN SUBARU ENGINE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION If the machine output is low this test will determine whether the gasoline engine high idle speed is set for the correct maximum RPM MATERIALS NEEDED Screwdriver Frequency Counter or Strobe tach or Oscilloscope Black or Red Marking Pencil 10mm Socket Wrench BULL
10. LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 69 2 2 a Return to Section TOC Return to Master TOC 5 o 2 r MAINTENANCE FIGURE D 7 MAJOR COMPONENT LOCATIONS CRADLE ASSEMBLY ROTOR BLOWER AND BEARING ASSEMBLY STATOR ASSEMBLY BRUSH BRUSH HOLDER ASSEMBLY AND BEARING BRACKET END COVER REAR CONTROL PANEL REAR PANEL ASSEMBLY FUEL TANK ASSEMBLY CONTROL PANEL ASSEMBLY ROOF ASSEMBLY SIDE PLATE MUFFLER AND ENGINE AIR DUCT AND FOAM ENGINE END BRACKETS MACHINING BULLDOG 140 LINCOLN B D 8 NOTES BULLDOG 140 LINCOLN HE D 8 DOL 19159 01 DOL 01 DOL 01 DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Master TOC Return to Master TOC o 5 o 2 c Return to Master TOC E TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation 22999 ne gow peed oe edison dees ey E 1 Engine Excitation Rotor And Stator E 2 Rotor Field Feedback And Auxiliary Power E 3 Weld Winding And Reactor seiret sprei kat enira E aaea ehh hn E 4 Auxili
11. Read and understand all safety instructions included in the engine manufacturers Operating and Maintenance Instructions manual that is shipped with the Bulldog 140 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f gt 0 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC BS OPERATION Ra BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL 1 Place the machine on a level sur face Open the oil fill plug Fill if necessary until oil flows out the top of the fill plug hole 4 Replace the fill plug and tighten securely CHECK AND FILL THE ENGINE FUEL TANK 1 Remove the fuel tank cap 2 Fill the tank to allow approximately 1 4 inch B mm of tank space for fuel expansion DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel tank cap and tighten securely NOTE The engine will operate satisfactorily on any gasoline meant for automotive use mini mum of 87 octane is recommended DO NOT MIX OIL WITH THE GASOLINE Use clean fresh lead free gasoline Leaded gasoline may be used if lead free is not available However lead free gasoline leaves fewer combustion deposits and gives longer valve life Purchase gasoline in quan tities that will be used within 30 days to assure fresh ness NOTE We DO NOT recommend using gasoline th
12. in the front 2 in the back 2 in the bottom ative terminal which will always be located Move the panel aside as far as the leads will diagonally across from the positive terminal alow Leads 9A and 7A are attached to the AC side of 4 Discharge the field capacitor by connecting the the bridge and are attached to the other two corner jumper wire clips on the black and the red wire terminals Either lead can go on either terminal terminals on the top of the capacitor See Figure F 13 for location Leave the clips on for at least 5 seconds then remove 5 The field diode bridge D1 is mounted to the 9 ied that Wn and TOF sheet metal just above the capacitor See Mg Figure F 13 Remove it using the phillips head 10 Replace the control panel and tighten the eio OJO f i cre 5 5 amp 8 Mount the field diode bridge using the screw Use the slot head screwdriver 9 screw driver sheet metal screws with the 5 16 nut driver sis 6 With the needlenose pliers gently remove the and 5 16 wrench 5 2 wires from the field diode bridge Note lead 11 Replace the top cover of the control box and gt locations tighten the sheet metal screws with the 3 8 9 nut driver c 5 5 dc BULLDOG 140 LINCOLN B F 40 NOTES BULLDOG 140 LINCOLN HE F 40 DOL 19159 01 DOL 01 DOL 01
13. 90 side view end view Correct Welding Position OPERATION 2 The Correct Way to Strike An Arc Be sure the work clamp makes good electrical contact to the work Lower your headshield and scratch the electrode slow ly over the metal and you will see sparks fly While scratching lift the electrode 1 8 8 2mm and the arc is established NOTE If you stop moving the electrode while scratch ing the electrode will stick Most beginners try to strike the arc by a fast jabbing motion down on the plate Result They either stick their electrode or their motion is so fast that they break the arc immediately 3 The Correct Arc Length The arc length is the distance from the tip of the elec trode core wire to the base metal Once the arc has been established maintaining the correct arc length becomes extremely important The arc should be short approximately 1 16 to 1 8 1 6 3 2mm long As the electrode burns off the electrode must be fed to the work to maintain correct arc length The easiest way to tell whether the arc has the correct length is by listening to its sound A nice short arc has a distinctive crackling sound very much like eggs frying in a pan The incorrect long arc has a hollow blowing or hissing sound 4 The Correct Welding Speed The important thing to watch while welding is the pud dle of molten metal right behind the arc DO NOT WATCH THE ARC ITSELF The appearance of the puddle and
14. OJO f i 0 olg 5 5 Dllo amp Return to Section TOC Return to Master TOC F 31 BRUSH REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in accessing the Generator Brushes for maintenance or replacement MATERIALS NEEDED Small Slot Head Screwdriver 1 4 Nutdriver Needlenose Pliers BULLDOG 140 LINCOLN B F 31 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 32 TROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT continued FIGURE F 10 BRUSHES RETAINED WITH CABLE TIE CABLE TIE
15. Recommended Applications eee 2 Operational Features and Controls B 2 Welding Capability pee rack ees eee oY pea Bede Meee eee ee eee B 2 Pcr PON ee ee oe ed aided Bee fed B 3 Controls and B 3 Welding Generator Controls 2 0 B 3 Gasoline Engine Controls Engine Operation B 4 Thru B 7 Welding Operation and Welding Guidelines B 8 Thru B 17 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E EM i olg 5 2 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC SAFETY INSTRUCTIONS Read and understand this entire section before oper ating your Bulldog 140 WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating g
16. Reduces engine noise output See SPARK ARRESTER in the INSTALLATION section of this manual 4 ON OFF Switch A two position switch located on the rear of the engine In the ON I position the engine ignition circuit is energized and the engine can be started by pulling the recoil rope starter In the OFF O position the electronic ignition is grounded and the engine shuts down 5 AIR CLEANER Filters intake air to the carburetor See in the MAINTE NANCE section of the engine owner s manual for details about the specific type of air cleaner to use 6 CHOKE Provides a richer air fuel mixture for cold engine starting conditions See the topic ENGINE OPERATION for details on setting the choke 7 RECOIL STARTER Manual rope type starter The handle position allows easy starting from either ground level or pickup truck level 8 OIL DRAIN PLUG Permits convenient draining of engine oil during maintenance Both sides of the engine are equipped with an oil drain plug 9 OIL FILL PLUG Permits convenient filling of engine oil during maintenance Both sides of the engine are equipped with an oil fill plug ENGINE OPERATION DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS The maximum allowable high idle speed for the Bulldog 140 is 3750 RPM no load Do NOT adjust the governor screw on the engine Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed
17. Slide in the gauge Then rotate the shaft 180 degrees and measure again If the gauge does not clear loosen the four end bracket thru bolts reposition the end bracket retighten the bolts and recheck the air gap Repeat until the prop er 010 minimum air gap is achieved Tighten the end bracket support nuts and lock washers Remove the 2 X 4 engine support 10 11 12 FEELER GAUGE STATOR ESS Reinstall the brush holder assembly Refer to the topic l BRUSH REMOVAL AND REPLACEMENT n this section of the manual Slide the control box back into place Pull the stator and ground wire up through Remove the control panel 2 screws and reconnect the output terminal leads W1 W2 Install a new cable tie to hold the leads togeth er Reconnect the stator wire harness molex coupling Install the 6 screws that hold the con trol panel to the box Connect the engine flywheel alternator cou pling Lift the control box and screw in the rubber mountings Set the control box onto the mountings Install the front left hand washer and nut that anchors the control box to the stator frame Position the reactor and install the remaining washers and nuts Check all terminal connections for clearance grounding and tightness Replace the top cover to the control box and tighten the 4 nuts Conduct the RETEST AFTER REPAIR pro cedure the following topic in this section of t
18. Start up Watts Continuous Surge Air Compressor 1 4 000 8 000 Air Compressor 3 4 HP 3 100 5 000 Airless Sprayer 1 3 HP 1 500 2 400 Chain Saw Circular Saw Coffee Maker Deep Freezer 750 2 000 Electric Motor 1 HP 2 500 4 000 Electric Range 1 element Electric Skillet Furnace Fan 1 3 HP 3 000 4 800 Portable Grinder 4 1 2 Portable Grinder 7 Halogen Work Light Hand Drill 1 4 Hand Drill 3 8 1500 Watt Heater Hedge Trimmer Light Bulb Reciprocating Saw Radial Arm Saw Radio Refrigerator Freezer small 1 500 2 400 Slow Cooker Submersible Pump 1 HP 2 500 4 000 Sump Pump 1 500 2 400 Toaster Weed Trimmer Lincoln Wire Feeder Welder NOTES Wattages listed are approximate Check your equipment for actual wattage Equipment with unusually high START UP WATTS are listed For start up of other tabled equipment that uses a motor allow up to 2 times the running watts shown above For example a 1 HP motor requires approximately 1000 watts of power when running but may require 2 5 X 1000 2500 watts or 4 0 X 1000 4000 watts to start Multiple loads can be used as long as the total load does not exceed 5 500 surge watts or 4 000 continuous watts Be certain to start the largest loads first Output rating in watts is equivalent to volt amperes at unity power factor res
19. This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN amp BULLDOG 140 G 3 ELECTRICAL DIAGRAMS G 3 SCHEMATIC COMPLETE MACHINE S28101 ENGINEERING CONTROLLED CHANGE DETAIL REVISED RHEOSTAT amp ROTOR LOAD INFORMATION MANUFACTURER No ADDED RHEOSTAT VALUE BLACK Y YELLOW L1 REACTOR ORANGE Y R YELLOW RED STRIPE Located inside back of control N C NO CONNECTION BLACK YELLOW STRIPE Return to Section TOC Return to Master TOC IF OIL LEVEL IS TOO LOW OIL LEVEL MAX SWITCH CLOSES GROUNDING RHEOSTAT RHEOSTAT ENGINE MAGNETO OIL LEVEL NO LOAD NO LOAD baownnsoo _ MODULE PREVENTING ENGINE an TET FROM STARTING OR RUNNING Located inside engine blower housing Located inside engine crankcase ii Mis ENGINE GROUND STUD ON 5 MODULE B MAGNETO CONTROL PANEL FRONT OIL LEVEL IGNITION 1 Qrauit Breaker located SPARK pane upper PLUG right hand corner G LEVEL STOP RUN SWITCH ND SWITCH GENERATOR Located an tap of engine blower housing D H SUPPORT right hand as viewed frombehind machine EN 130 VACQ MAX 5 9 4 G NO LOAD Ardy 5 d a J6 130 VAC 4 NEUTRAL STU LEAD 7 DISCONNECTED AND ENGINE RUNNING ON CONTROL E NO LOAD EE AT 37
20. and thinner FLEETWELD 180 3 32 70 amps AWS E6011 Lincoln 7018 AC 90 amps AWS E7018 3 16 Maximum FLEETWELD 37 1 8 125 amps AWS E6013 5 16 Maximum FLEETWELD 180 1 8 90 amps AWS E6011 Any Thickness WEARSHIELD ABR 1 8 100 amps NOTES Stick Welding The values listed are suggested settings Actual setting may vary depending on individual preference and or specific application Beginners should use Lincoln E7018 AC For electrodes not listed follow tables that are packed with the electrodes Ask for the Lincoln WELD DIRECTORY Publication C2 10 for a complete listing of all Lincoln stick elec trodes available AWS American Welding Society A WARNING ARC RAYS can burn When using an open arc process it is necessary to use correct eye head and body protection NM Semi automatic Wire Welding With a Lincoln Wire Feeder Welder The Bulldog 140 generator power can be used to supply power up to 4 000 watts continuous input power to a Lincoln Wire Feeder Welder The Wire Feeder Welder is equipped with all the supplies need ed for Flux Cored Arc Welding FCAW Also some Wire Feeder Welders come equipped with the essen tials needed for Gas Metal Arc Welding GMAW or MIG processes while others require the purchase of a conversion kit These products are available where Lincoln products are sold Contact your local autho rized Lincoln representative for more details Stick welding is probably the mo
21. as this makes the entire process very complicated and difficult to learn 6 If the upward motion of the arc is done correctly with a wrist motion the arc will automatically become a long arc that deposits little or no metal See drawing above 7 During this entire process the ONLY thing to watch is the molten metal As soon as it has solidified the arc is SLOWLY brought back and another few drops of metal are deposited DO NOT FOLLOW THE UP AND DOWN MOVEMENT OF THE ARC WITH YOUR EYES KEEP THEM ON THE MOLTEN METAL OPERATION 8 When the arc is brought back to the now solidified B 14 puddle IT MUST BE SHORT otherwise no metal will be deposited the puddle will melt again and it will drip 9 Itis important to realize that the process consists of SLOW DELIBERATE movements There are no fast motions Vertical Down Welding Vertical down welds are applied at a fast pace These welds are therefore shallow and narrow and are excel lent for sheet metal Do not use the vertical down tech nique on heavy metal The welds will not be strong enough 1 Use 1 8 3 2m or 3 32 2 5mm AWS 6011 2 On thin metal use 70 75 amps 14 75 A 16 ga 60 3 Hold the electrode in a 30 45 angle with the tip of the electrode pointing upwards 4 Hold a VERY SHORT arc but do not let the elec trode touch the metal Very 5 up and down whipping short motion will help prevent arc bur
22. it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 If you will be storing the machine for over 30 days you should drain the fuel to protect fuel system and carburetor parts from gum deposits Empty all fuel from the tank and run the engine until it stops from lack of fuel 3 You can store the machine for up to 24 months if you use a gasoline stabilizing additive in the fuel system Mix the additive with the fuel in the tank and run the engine for a short time to circulate the additive through the carburetor 4 While the engine is still warm drain the oil and refill with fresh oil per the engine manual 5 Remove the spark plug and pour approximately 1 2 ounce 15 ml of engine oil into the cylinder Replace the spark plug and crank the engine slow ly to distribute the oil 6 Clean any dirt and debris from the cylinder and cylinder head fins and housing rotating screen and muffler areas 7 Store a clean dry area BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO gt olg 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC Bet INSTALLATION aid STACKING Bulldog 140 machines CANNOT be stacked TILTING Place the machine on a secure level surface whenev er you use it or store it Any surfaces you place
23. ness of the work and the size and type of rod you re using TO USE THE Bulldog 140 FOR WELDING 1 Remove the flange nuts from the weld output ter minals and place the work and electrode welding cables over the terminals See Figure B T Replace and tighten the flange nuts securely Be sure the connections are tight 2 Select the appropriate electrode See Table B 2 WELDING APPLICATIONS or the ELECTRODE SELECTION GUIDE on the machine Output Control Panel 3 Attach the work clamp securely to the work you are welding 4 Insert the electrode into the electrode holder Set the current control dial to the desired output current 6 Start the gasoline engine See ENGINE OPERA TION in this section of the manual 7 Strike an arc and begin welding For information on welding techniques see WELDING GUIDE LINES this section of the manual AFTER YOU FINISH THE WELD 1 Stop the gasoline engine See ENGINE OPERA this section of the manual Allow the electrode and work to cool completely Remove the work clamp from the work Remove any remaining piece of electrode from the electrode holder 5 If you are finished using the Bulldog 140 for weld ing disconnect the welding cables from the weld output terminals Reattach the flange nuts and leave them on the terminals NOTE 1 Welding current is continuously variable with 6096 duty cycle applying to output currents 100 Amps and less and 3096 dut
24. remove the rotor thru bolt See Figure F 18 If an impact wrench is not available use the 1 2 box wrench Hold the rotor with one hand and shock the wrench with the mallet to loosen the thru bolt The thru bolt has a star washer and lock washer beveled to conform to the rotor shaft Pull out the thru bolt Install the long thru bolt supplied with Lincoln Electric Rotor Removal Kit S20925 The slot head must face out Screw in the bolt with the slot head screw driver until the bolt bottoms out on the engine crankshaft about 3 4 Turning it counterclockwise screw in the reverse thread bolt from the kit into the rotor shaft until it bottoms out on the thru bolt With an impact wrench tighten the reverse thread bolt until the rotor pops off the engine crankshaft If an impact wrench is not available use the 1 2 box wrench Hold the rotor with one hand and shock the wrench with the mallet until the rotor pops off the engine crankshaft 6 Slide the rotor and blower press fitted to the rotor the rest of the way off the crankshaft REASSEMBLY PROCEDURE 1 Lubricate the tapered engine crankshaft Slide the rotor onto the shaft Coat the rotor thru bolt threads with Lincoln E177 R retaining compound Locktite 277 Place the beveled lock washers onto the thru bolt and insert it into the rotor shaft Hold the rotor and tighten the thru bolt to 22 25 ft 165 Carefully install the stator with th
25. tical up or vertical down Vertical up is used whenever a large strong weld is desired Vertical down is used primarily on sheet metal for fast low penetrating welds BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO gt 2 0 5 2 amp Return to Section TOC Return to Master TOC B 14 Vertical Up Welding The problem when welding vertical up is to put the molten metal where it is wanted and make it stay there If too much molten metal is deposited gravity will pull it downwards and make it drip Therefore a certain technique has to be followed Short arc NOTE Holder end of electrode is lower than arc 1 Use 1 8 8 2mm 90 115 amps or 3 32 2 5mm 70 amps AWS 6011 2 When welding the electrode should be kept hori zontal or pointing slightly upwards See drawing above 3 The arc is struck and metal deposited at the bottom of the two pieces to be welded together 4 Before too much molten metal is deposited the arc is SLOWLY moved 1 2 3 4 12 20mm upwards This takes the heat away from the molten puddle which solidifies If the arc is not taken away soon enough too much metal will be deposited and it will drip 5 The upward motion of the arc is caused by a very slight wrist motion Most definitely the arm must not move in and out
26. 2 Check the welding cables Check continuity zero ohms of clamps and electrode holder for lead W1 black from reactor loose or broken connections L1 to stator winding See the Wiring Diagram Check reactor L1 for continuity of winding See the Wiring Dia gram Check the stator for continuity of winding See the Wiring Dia gram Make certain the reactor and or stator are NOT grounded Mini mum acceptable resistance to ground is 500 K ohms A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC F 7 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S OUTPUT PROBLEMS No auxiliary power welding output 1 Check circuit breakers CB1 and CB2 Reset if tripped is normal engine runs normally Make sure that the control rheo stat R1 is set at GENERATOR maximum RECOMMENDED COURSE OF ACTION Check the auxiliary power re ceptacles and associated wires for loose or faulty connections Check the continuity zero ohms of leads 3 3A black 6 6A yellow and 5 white from the receptacles to the sta
27. 2 Safety Precautions Exerc auc PMG pen D A 3 Location and Ventilation s eek eot caus tek ER REE REPRE CRGO pe d X A 3 leni m ERIT a eee eee ee 3 Stacking tilting and Lifting hn A 4 Pre operation Engine Service tte eae A 4 Oil Fuel and Spark Arrester 02 aedes ek eed EET PE Pa race A 4 Electrical Output Connections hh A 5 Welding Cable Connections cette tee A 5 Electrical Connections s eu Paes hee ele PEERS ee Adee NO NP Ee EA qa ea A 6 Machine Grounding ru eu preme A 6 Plugs And Hand Held Equipment A 6 Auxiliary Power Receptacles ccc teen A 6 Premise WINING RE AR 7 Circuit Breakers oss A 7 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 Return to Section TOC Return to Master TOC o 5 o E 2 r 2 INSTALLATION TECHNICAL SPECIFICATIONS Bulldog 140 K2708 1 INPUT GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Robin Subaru 1 cyl 3700 RPM 17 51 cu in Manual Fuel 6 86 gal 24 9 EX 30 4 c
28. 90 side view Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates Penetration Unless a weld penetrates close to 100 a butt joint will be weaker than the material welded together 1 2 4 4 12 Poor 12mm 6mm 1 4 6mm In this example the total weld is only 1 2 the thickness of the material thus the weld is only approximately half as strong as the metal Good In this example the joint has been flame beveled or ground prior to welding so that 100 penetration could be achieved The weld if properly made is as strong or stronger than the original metal t 1 8 3 2mm Successive passes must be used to build up butt welds on heavier metal OPERATION Fillet Joints Now weld the two plates together Weld from left to When welding fillet joints it is very important to hold the electrode at a 45 angle between the two sides or the metal will not distribute itself evenly To make it easier to get the 45 angle it is best to put the electrode in the holder at a 45 angle as shown Multiple Pass Welds Make multiple pass horizontal fillets as shown in the sketch Put the first bead in the corner with fairly high current Hold the electrode angle needed to deposit the filler beads as shown putting the final bead against the vertical plate e S rep 773 Welding in the Vertical Position Welding in the vertical position can be done either ver
29. BRUSHES PROCEDURE Remove the spark plug wire Open the brush holder assembly cover Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fingernail The cover will drop open on its bottom hinge With the 1 4 nut driver remove the 2 screws that hold the brush holder assembly in place With the needlenose pliers gently remove the black and the red wires NOTE The red wire is inboard RED is marked on the brush holder beside the terminal for the red wire To change the brushes use the slot head screw driver to pop off the plastic retainer on the back of the brush holder assembly Remove the old brush assemblies and insert the new ones One corner of the terminal clip is beveled so that the brush can go in only one Way Snap the plastic retainer back onto the brush holder The brushes may need some reposi tioning wiggle them slightly to help them seat properly on the slip rings BULLDOG 140 LINCOLN B F 32 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio f i 0 olg 5 2 amp Return to Section TOC Return to Master TOC F 33 TROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT continued 8 To reinstall the brush holder assembly depress the spring loaded brushes into the holder and slip a suitable non metallic fairly stiff r
30. Call 1 888 935 3877 BULLDOG 140 LINCOLN B F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 a Return to Section TOC Return to Master TOC 5 o 2 TROUBLESHOOTING REPAIR Fs PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK e can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 Ifthe problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap
31. D 2 PEE debe tetas Bee D 3 Routine and Periodic Maintenance D 3 thru D 6 General Assembly Exploded View ete D 7 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 69 2 a Return to Section TOC 5 o 2 r Return to Master TOC D 2 MAINTENANCE D 2 Service Instructions Single and Two Stage Engine Air Cleaners 1 Remove the Filter Unfasten or unlatch the sc service cover Because amp the filter fits tightly over the outlet tube to create the critical seal there will be some initial resistance similar to breaking Rotate the the seal on a jar Gently move the end of the filter filter while back and forth to break the seal then rotate while pulling pulling straight out Avoid knocking the filter straight out against the housing If your air cleaner has a safety filter replace it every third primary filter change Remove the safety filter as you would the primary filter Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine Clean Both Surfaces of the Outlet Tube and Check the Vacuator Valve Use a clean cloth to wipe the filter sealing surface and th
32. Electrical loads in watts are approximately calculated by multiplying the voltage rating of the load by the num ber of amps it draws This information is given on the load device nameplate For example a device rated 120 volts 2 amps will need 240 watts of power 120 x 2 240 You can use to determine the wattage require ments of the most common types of loads you can power with the Bulldog 140 Be sure to read the notes at the bottom of the table TO USE THE Bulldog 140 AS AN AUXILIARY POWER SUPPLY 1 Start the gasoline engine See ENGINE OPERA this section of the manual the engine owner s manual 2 Set the current control dial on the output control panel to GENERATOR See Figure B 1 3 Plug the load s into the appropriate 120 volt or 240 volt power receptacle NOTE During welding the maximum generator out put for auxiliary loads is 100 watts NOTE You can supply multiple loads as long as the total load does not exceed 5 500 surge watts or 4 000 Continuous watts Be sure to start the largest loads first BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO i c 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC add OPERATION 1 GENERATOR POWER APPLICATIONS Suggested Power Applications Running Watts
33. TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt 2 0 Oo 5 5 Dllo amp Return to Section TOC Return to Master TOC B 10 No one can learn to weld simply by reading about it Skill comes only with practice The following pages will help the inexperienced welder understand welding and develop his skill For more detailed information order a copy of the book New Lessons in Arc Welding See Book Division section at rear of manual The operator s knowledge of arc welding must go beyond the arc itself He must know how to control the arc and this requires a knowledge of the welding cir cuit and the equipment that provides the electric cur rent used in the arc Figure 3 is a diagram of the weld ing circuit The circuit begins where the electrode cable is attached to the welding machine and ends where the work cable is attached to the machine Current flows through the electrode cable to the electrode holder through the electrode holder to the electrode and across the arc On the work side of the arc the current flows through base metal to the work cable and back to the welding machine The circuit must be complete for the current to flow To weld the work clamp must be tightly connected to clean base metal Remove paint as necessary to get a good connection Connect the work clamp as close as possible to the area you a
34. The gasoline engine must be OFF to install weld ing cables 2 Remove the 1 2 13 flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld output terminals You can connect either cable to either terminal since the Bulldog 140 provides AC weld current Tighten the flanged nuts securely Be certain that the metal piece you are welding the work is securely connected to the work clamp and cable 6 Check and tighten the connections periodically CAUTION Loose connections will cause the output termi nals to overheat The terminals may eventually melt Do not cross the welding cables at the output ter minal connection Keep the cables isolated and separate from one another Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the ACCES SORIES section of this manual for more information ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is con nected to premises wiring home shop etc To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must WARNING 1 Be grounded to the frame of the welder using a grounded type plug 2 Be double insulated Do not ground the machine to a pipe that carries explosive or com
35. gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from
36. important questions because the cost quality and appearance of your work depends on proper electrode selection and application MILD STEEL ELECTRODES may be classified into the following groups Out of Position Group AWS E6011 This group includes electrodes which have a snappy deep penetrating arc and fast freezing deposits These electrodes are used for general purpose all position fabrication and repair welding They are also the best choice for pipe welding and sheet metal butt corner and edge welds They can be used for repair work when dirt grease plating or paint cannot be com pletely cleaned from the steel These electrodes are typically used with motions A and B see drawing for the first pass on vertical up welds This group includes electrodes which have a moder ately forceful arc and deposit rates between those of the out of position and high deposit electrodes They are primarily general purpose production elec trodes especially for downhill fillets and laps or short and irregular welds that change direction or position They are also widely used in maintenance and recom mended for sheet metal fillet and lap welds Motion D see drawing is generally used for vertical up welding but motions A and B are also suitable Low Hydrogen Group AWS E7018 These electrodes are generally called hydrogen The name comes from the fact that their coating con tains little hydrogen in either mois
37. it on other than the ground must be firm non skid and structurally sound The gasoline engine is designed to run in a level posi tion for best performance It can operate at an angle but this should never be more than 15 degrees in any direction If you do operate it at a slight angle be sure to check the oil regularly and keep the oil level full Also fuel capacity will be a little less at an angle LIFTING The Bulldog 140 should be lifted by two people See Specification section for weight The LowLift grab bars on both ends make lifting easier PRE OPERATION ENGINE SERVICE Read and understand the engine operating and maintenance instructions supplied with this machine before you operate the Bulldog 140 A WARNING Keep hands away from muffler or HOT engine parts Stop the engine when fueling Do not smoke when fueling Remove fuel cap slowly to release pressure Do not overfill tank Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank Er linrra away rng DATOS Handed while tewiing uel ans allow to clear 24901 IKE cute fine een Or tapos W cH wiles whan imsapariig ar mA machine OIL The Bulldog 140 is shipped with the engine filled with SAE 10W30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE This is an added precau tion Do not screw in d
38. level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC SAFETY i WELDING and CUTTING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adJacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed
39. open arc welding Headshield and filter lens should conform to ANSI 287 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure
40. peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier i SAFETY iv 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les g
41. receptacles and offer 5500 watts total of AC power NOTE Unshaded areas of Block Logic Diagram are the subject of discussion BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f i 0 Of dc gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC ET THEORY OF OPERATION EN FIGURE E 4 WELD WINDING REACTOR AND AUXILIARY POWER OVERCURRENT PROTECTION ENGINE MECHANICAL ROTATION CAPACITOR RHEOSTAT WELD WINDING AND REACTOR The AC voltage developed in the stator weld winding is delivered through the reactor to the machine output terminals The BULLDOG 140 provides the user up to 125 amps of constant current AC welding for stick elec trodes The reactor stores energy and this energy is released into the welding arc when the AC voltage passes through the zero point In this manner the reactor enhances and stabilizes the AC welding arc The reactor is designed to provide optimum welding characteristics when used with the recommended elec trodes REACTOR OUTPUT TERMINALS 115 AND 230VAC RECEPTACLES BRIDGE AUXILIARY POWER OVERCURRENT PROTECTION The 4000 watt auxiliary power winding and circuitry is protected from an overload condition by two 20 amp circuit breakers The circuit breakers are located below the output receptacles They can be manually reset NOTE Uns
42. repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in accessing and removing the Output Control Rheostat for maintenance or replacement MATERIALS NEEDED 3 8 Nutdriver 5 16 Nutdriver Small Slot Head Screwdriver 9 16 Open or Box End Wrench 5 16 Open or Box End Wrench Needlenose Pliers Wiring Diagram BULLDOG 140 LINCOLN B F 35 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 36 indi TROUBLESHOOTING AND REPAIR RHEOSTAT REMOVAL AND REPLACEMENT continued FIGURE F 11 RHEOSTAT REMOVAL PROCEDURE 1 Remove the spark plug wire T 2 With the 3 8 nut driver remove the 4 sheet metal screws that hold the top cover to the con trol box Remove the top cover 3 With the small slot head screw driver l
43. the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 0 c 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC i TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage Contact the Lincoln Electric Service is evident Department at 888 935 3877 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely co
44. the share on a brick See drawings Most users will want to hardface the underside of the share but some might find that the wear is on the top side The important thing is to hardface the side that wears 3 Use 1 8 3 2mm Wearshield at 80 100 A Strike the arc about one inch from the sharp edge BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO gt 2 0 Oo 55 gt amp c Return to Section TOC Return to Master TOC B 16 OPERATION B 16 4 The bead should be put on with a weaving motion and it should be 1 2 3 4 12 7 19 0mm wide Do not let the arc blow over the edge as that will dull the edge See drawing below Strike Arc Work Table H ere Sharp Edge 255 i 1 2 3 4 width Plow Share 12 20mm Positioning of Share Weaving Motion 5 Use the back stepping method Begin to weld 3 76mm from the heel of the share and weld to the heel The second weld will begin 6 152mm from the heel the third weld 9 229mm from the heel etc B C D E 3 75mm First weld from A to B then from C to A then from D to C then from E to D and so on BACKSTEPPING Backstepping greatly reduces the chances for cracking of the share and it also greatly reduces warping NOTE The entire process is rather fast Many begin ners go much too slowly when hardfac
45. the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use
46. 00 RPM 0 15 0 25 AMPS 205 FLASH FROM MAX RHEOSTAT FIELD AMPS RNEOSTAT ENGINE MAGNETO 5 75 6 0 75 deg F 4 25 TO 4 5 OPERATING E a 2 2028 2 202C TEMPERATURE 20 Q 2004 Pheostat located 202A on contra pana CW Onc 37570425 EXCITER VDC WINDING RHEOSTAT Excitation rectifier located in Flashing rectifier and MAX Return to Section TOC Return to Master TOC FRAME GROUND FLASHING AMPS TO ROTOR WITH GENERATOR enclosure on sheet metal filter capacitor RHEOSTAT near rectifier located in enclosure behind contro panel 201A in molded plasti 201 ia REVOLVING FIELDS 201D ROTOR 7 OHMS 75 F 9 OHMS OPERATING TEMPERATURE eio gt 2 0 olg 1 5 5 Dllo amp THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC ON PLACE DECIMALS 5s 02 205 mn NONE EQUIPMENT TYPE BULLDOG 140 PAGE 1 or 1 in 2 SO T PRINTED CUB JECT MACHINE SCHEMATIC E A4 SIZE NUMBER REVISION MATERIAL TOLERANCE t TO AGREE ENGINEER A WITH PUBLISHED STANDARDS PM UNITS REFERENCE DO NOT SCALE THIS DRAWING APPROVED DRS INCH 7 31 2009 Nu iEn CRM40760 A S28100 5281
47. 01 B NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 BULLDOG 140 Return to Section TOC Return to Master TOC
48. COMMENDED APPLICATIONS GENERATOR The Bulldog 140 gives AC generator output for medi um use non commercial demands For more details on operating the generator see GENERATOR OPERA TION in the OPERATION section of this manual WELDER The Bulldog 140 provides excellent constant current AC welding output for stick GMAW welding For more details on using the machine as a welder see WELD ING in the OPERATION section of this manual OPERATIONAL FEATURES AND CONTROLS The Bulldog 140 was designed for simplicity Therefore it has very few operating controls A single dial on the control panel lets you select either genera tor or welding use For welding the same dial selects continuous current output over the machine s 70 to 125 amp range The gasoline engine controls include a recoil starter choke and rotary stop switch See ENGINE OPERA TION in the OPERATION section of this manual and the engine owner s manual for details about starting running stopping and breaking in the gasoline engine WELDING CAPABILITY The Bulldog 140 is rated 125 amps 20 volts at 30 duty cycle on a ten minute basis This means that you can load the welder to 125 amps for three minutes out of every ten minute period The machine is also capa ble of higher duty cycles at lower output currents You can load the welder to 100 amps for six minutes out of ten for a 6096 duty cycle The current is continu
49. DOG 140 LINCOLN B F 25 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 Of dc 5 5 Dllo 2 c Return to Section TOC Return to Master TOC Return to Master TOC F 26 TROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN SUBARU ENGINE continued FIGURE F 7 MARK LOCATION MARK PROCEDURE This test can be conducted by any of three meth ods Strobe tach Method 1 Stop the engine and remove the spark plug wire to prevent accidental kickback or starting With the black or red marking pencil place a mark on one of the blower which can be reached through the vent slots in the end bracket See Figure F 7 Connect the strobe tach according the manu facturer s instructions Reconnect the spark plug wire and start the engine Direct the strobe tach light on the blow er paddle and synchronize it to the rotating mark The tach should read 3700 RPM Using the 10mm socket wrench slightly loosen the throttle locking nut See Figure F 8 Using the screwdriver adjust the high speed stop screw until the tach reads 3700 RPM See Re tighten the throttle locking nut Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacl
50. For safety use a 1 Meg ohm resistive cord connected ATTENTION to a grounded part of the Static Sensitive frame Devices If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with
51. H DOL uonoeg DOL 5 DOL 5 DOL 5 Gri TABLE OF CONTENTS DIAGRAM SECTION ol o o Electrical Diagrams xxr Re ewer dooce papse xe ex DIN ES G 1 gt 9 Wiring Diagram L15064 o ou wo x 904 X Vance AOL Flour eb e wat ud G 2 HB Schematic Complete Machine 828101 G 3 Return to Master TOC o 5 o 2 t Return to Master TOC BULLDOG 140 LINCOLN B G 2 ELECTRICAL DIAGRAMS me WIRING DIAGRAM COMPLETE MACHINE L15064 WIRING DIAGRAM BULLDOG 140 Return to Section TOC Return to Master TOC 205 gt 200A pia 202A of i 201D O 201A Return to Section TOC Return to Master TOC GROUND STUD ON GENERATOR CONTROL PANEL FRONT SUPPORT FRAME 191 GROUND 20A J6 U 240 VAC NEUTRAL STUD ENGINE WIRING ON CONTROL i PANEL BOTTOM Si e 5 MODULE 1 0 LOWOIL RUNSTOP ENGINE DENN d SWITCH 1 SWITCH f V D REACTOR L1 OUTPUT TERMINALS WORK eio gt 2 c 1 5 5 Dllo amp c L15064 A Return to Section TOC Return to Master TOC NOTE
52. LLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio EC te 2 olg fom 3 cre 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC TER TROUBLESHOOTING AND REPAIR ins NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD CH1 O volts This is the typical AC output voltage generated from a properly operating machine Note that each vertical divi sion represents 50 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal BULLDOG 140 LINCOLN B nae TROUBLESHOOTING AND REPAIR Peg NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD 1 Period 16 2 ms 3700 rpm XL _ E Return to Section TOC Return to Master TOC O volts Return to Master TOC Return to Section TOC 20 volts 5ms This is the typical AC output voltage generated from a properly operating machine Note that each vertical divi sion represents 50 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes c
53. NOTES BULLDOG 140 LINCOLN HE F 20 DOL 19159 01 DOL 01 DOL 01 DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 21 ROTOR RESISTANCE TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there is a shorted winding in the Rotor or if the Rotor is ground ed MATERIALS NEEDED Volt Ohmmeter 1 4 Nutdriver Small Slot Head Screwdriver Wiring Diagram BULLDOG 140 LINCOLN B F 21 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Mas
54. PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed
55. Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http Awww lincolnelectric com safety for additional safety information BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et san
56. Remove the top cover nuts and washers that anchor the control box to the stator frame Two of the nuts also anchor the reactor The reactor must be moved over to access the front left hand nut anchoring the control box Be careful not to drop the washers into the machine Liftup the control box and unscrew the 4 rubber mounts Set the control box onto the stator frame for the moment Pull apart the molex coupling that connects the stator to the wiring harness With the slot head screw driver remove the 6 sheet metal screws that hold the control panel to the control box 3 on each side You may need to use the 5 16 end wrench on the engine side because of limited clearance Pull the panel away from the control box With the 9 16 open end wrench remove lead W2 Black from the output terminal See Figure F 16 for location With the diagonal cut ters cut the cable tie that holds the two output OUTPUT TERMINALS leads together Pull lead W2 back out of the way screw the bolt back into the output termi nal hole loosely for reassembly Set the control panel back on the control box and hold it in place with 1 sheet metal screw in each side Remove the brush holder assembly Open the brush holder assembly cover Squeeze the 2 tabs and depress the cover at the top with a Screw driver or your fingernail The cover will drop open on its bottom hinge With the 1 4 nutdriver remove the 2 screws
57. STEM 1 REMOVE DIRT LOWER AREA AND DEBRIS FROM THIS BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 2 0 dc 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC Ds MAINTENANCE SPARK PLUG SERVICE To service spark plug remove the 8 screws securing the side panel See Figure D 4 FIGURE D 4 SIDE PANEL SCREW LOCATIONS CLEAN OR REPLACE SPARK PLUG Clean or replace the spark plug after every 100 hours of opera tion or every season whichever comes first Do not blast the spark plug clean with an abrasive cleaning device Clean the plug by scraping it or by using a wire brush Wash the plug with a commercial solvent After cleaning or when installing a new spark plug set the terminal gap to 025 inch 65 mm with a feeler gauge See Figure D 5 FIGURE D 5 SET SPARK PLUG GAP Use the engine owner s manual for latest Plug Gap Info CLEAN SPARK ARRESTER SCREEN Refer to the engine owner s manual that was shipped with your Bulldog 140 for the proper cleaning instructions TABLE D 1 ENGINE MAINTENANCE PARTS ROBIN SUBARU PART SPARK PLUG Champion RL 86C GAP 025 65mm AIR FILTER ELEMENT 279 32612 08 Refer to Table D 1 for engine maintenance parts The part numbers are accurate at the time of printing Veri
58. SVM208 A BULLDOG 140 For use with machine code number 11518 Return to Master TOC View Safety Info Cy lt Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS Return to Master TOC View Safety Info EQUIPMENT WITHOUT READ iS ING THIS MANUAL AND THE NS SAFETY PRECAUTIONS lt lt mA TAINED THROUGHOUT And AS Ss most importantly think before you CS Ss act and be careful SU View Safety Info S 5 o gt 2 tc SERVICE MANUAL View Safety Info LI NCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC Return to Master TOC Return to Master TOC o 5 o 2 Return to Master TOC i SAFETY i WARNING CALIFORNIA PROPOSITION 65 WARNINGS 1 Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The Above Fo
59. TERMINALS 2 GROUND STUD CIRCUIT BREAKER 20 Amp gt ELECTRICAL OUTPUT CONNEC TIONS See Figure A 1 for the location of the current control dial weld output terminals ground stud circuit break ers 240 and 120 volt receptacles WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that are large enough The correct size and length becomes especially impor tant when you are welding at a distance from the welder Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops B 5 RECEPTACLE 240 VOLT 50 AMP 6 DUPLEX RECEPTACLE 2 120 VOLT 20 AMP 7 HOUR METER TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable 125 Amps Length 30 Duty Cycle 0 50 ft 6 AWG 0 15m 200 250 ft 61 76m BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e He 2 Return to Section TOC Return to Master TOC 5 o E 2 r gt INSTALLATION Ab Cable Installation Install the welding cables to your Bulldog 140 as fol lows See Figure A 1 for the location of parts 1
60. alvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004
61. arc is very bright as well as hot and cannot be looked at with the naked eye without risking painful and possibly permanent injury A very dark lens specifically designed for arc welding must be used with the handshield or headshield whenever viewing the arc The arc melts the base metal and actually digs into it much like water through a garden hose nozzle digs into the earth The molten metal forms a pool or crater and tends to flow away from the arc As it moves away from the arc it cools and solidifies Slag forms on top of the weld to protect it during cooling Covering Electrode FIGURE 4 The welding arc BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 69 2 a Return to Section TOC Return to Master TOC 5 o 2 r B 11 The function of the covered electrode is much more than simply to carry current to the arc The electrode is composed of a core metal wire around which has been extruded and baked a chemical covering The core wire melts into the arc and tiny droplets of molten metal shoot across the arc into the molten pool The elec trode provides additional filler metal for the joint to fill the groove or gap between the two pieces of the base metal The covering also melts or burns in the arc It has several functions It makes the arc steadier pro vides a shie
62. ary Power Overcurrent Protection hn E 4 FIGURE E 1 BLOCK LOGIC DIAGRAM REACTOR OUTPUT TERMINALS STATOR ENGINE MECHANICAL ROTATION MAGNETO 115 AND 230VAC RECEPTACLES RHEOSTAT BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E EM i Of dc 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC EM THEORY OF OPERATION E FIGURE E 2 ENGINE EXCITATION ROTOR AND STATOR ENGINE MECHANICAL ROTATION MAGNETO CAPACITOR RHEOSTAT ENGINE EXCITATION ROTOR AND STATOR A small voltage developed by the engine magneto is fed through a diode to the rotating field coil in the rotor via a brush and slip ring configuration This excitation flashing voltage magnetizes the rotor lamination The rotor is mechanically coupled to the engine The rotating magnet induces a voltage in the stationary windings of the main alternator stator REACTOR OUTPUT TERMINALS 115 AND 230VAC RECEPTACLES BRIDGE Three separate and isolated windings are incorporated in the stator lamination assembly Each winding set has a different number of turns producing different magnitudes of AC output voltages The three windings are the weld winding the auxiliary power winding and the field feedback winding The field feedback winding provides rotor current durin
63. at contains alcohol such as gasohol However if gasoline with alcohol is used it MUST NOT contain more than 1096 Ethanol and MUST be removed from the engine during storage DO NOT use gasoline containing Methanol STARTING THE ENGINE NOTE Remove all loads connected to the AC power receptacles before starting the gasoline engine Put the ON OFF Switch in the ON I position FOR A COLD ENGINE 1 Open the fuel shutoff valve 2 Place the choke lever in the CHOKE position 3 Pull slightly on the recoil starter handle until resis tance is felt 4 Pull the cord rapidly 5 Ifthe engine does not start open the choke slight ly and pull the starter cord rapidly again When the engine starts gradually open the choke to the RUN position To open the choke fully requires an engine warm up period of several sec onds to several minutes depending on the tem perature After starting the engine first open the choke toward RUN until the engine just begins to run smoothly Then open the choke in small steps allowing the engine to accept small changes in speed and load until the choke is fully open in RUN During engine warm up the equipment can be operated FOR A HOT ENGINE 1 Open the fuel shutoff valve 2 Place the choke lever in the RUN position Closing the choke of a hot engine will flood the carburetor and prevent starting 3 Pull slightly on the recoil starter hand
64. bustible material When the Bulldog 140 is mounted on a truck or a trailer the machine generator ground stud MUST be securely connected to the metal frame of the vehicle See he ground stud is marked with the symbol PLUGS AND HAND HELD EQUIPMENT For further protection against electric shock any elec trical equipment connected to the generator recepta cles must use a three blade grounded type plug or an Underwriter s Laboratories UL approved double insu lation system with a two blade plug Ground fault protection is recommended for hand held equipment WARNING Never operate this machine with damaged or defective cords All electrical equipment must be in safe condition AUXILIARY POWER RECEPTACLES The control panel of the Bulldog 140 features two auxiliary power receptacles A20 amp 120 volt duplex double outlet receptacle A20 amp 240 volt simplex single outlet receptacle Through these receptacles the machine can supply up to 4 000 rated continuous watts and 5 500 surge watts of single phase AC power BULLDOG 140 LINCOLN PREMISES WIRING The Bulldog 140 is not recommended for premises wiring The Bulldog 140 does not have a combined 120 240 volt receptacle and cannot be connected to a premises as described in other Lincoln literature Remember that the Bulldog 140 is intended only for backup intermittent use power Return to Section TOC Return to Master TOC
65. cian in determining if the Generator Field is operating properly MATERIALS NEEDED Volt Ohmmeter 3 8 Nutdriver Wiring Diagram BULLDOG 140 LINCOLN B F 13 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i cre 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 14 TROUBLESHOOTING AND REPAIR ROTOR VOLTAGE TEST continued FIGURE LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST LEAD 200A CONNECTION PROCEDURE 1 With the 3 8 nut driver remove the 4 sheet metal screws that hold the top cover to the con trol box Remove the top cover Start the machine and run it at high idle Set the output control rheostat at the MAXIMUM or GENERATOR setting 3 Set the volt ohmmeter at the DC position Place the positive probe on lead 200A Blue and Brown wires joined together where it con nects at the back of the rheostat See Figure F 1 for location Place the negative probe on the machine ground stud or any other good unpainted ground GROUND STUD Check the voltage reading on the volt ohmme ter It should read 37 5 42 5 VDC If the voltage is low or not present the genera tor field circuit is not functioning correctly Proceed with the Rotor Resistance Test C1 R1 or D2 may also be faulty If rotor v
66. ckstepping After welding Cast Iron protect the casting against fast cooling Put it in a container of warm dry sand or lime If sand or lime is not available cover it with sheet metal or any other non flammable material that will diminish drafts and retain heat Cast Iron Plate Preparation Wherever practical the joint to be welded should be veed out by grinding or filing to give complete pene tration as shown in figures a b and c below This is especially important on thick castings where maxi mum strength is required BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio C te 2 olg 5 5 amp Return to Section TOC Return to Master TOC B 17 OPERATION High Speed Group AWS E6013 In some instances a back up strip may be used and z plates may be gapped 1 8 3 2mm or more as shown in figure b mE Scrap cz RS up strip Three ways to prepare plates where complete penetration is necessary On sections where only a sealed joint is required and strength is not important the joint may be welded after slightly veeing out the seam as shown in figure d below d Single and double beads with and without beveling for tight partial strength joints Selecting Electrodes Which electrode is best for the particular job how do you use it These are
67. completely into the air cleaner housing before securing the cover in place The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty If the service cover hits the filter before it is fully in place remove the cover and push the filter by hand further into the air cleaner and try again The cover should go on with no extra force Once the filter is in place secure the service cover Caution NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty 6 Check Connectors for Tight Fit Make sure that all mounting bands clamps bolts and connections in the entire air cleaner system are tight Check for holes in piping and repair if needed Any leaks in your intake piping will send dust directly to the engine BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 0 9 1
68. controlling the temperature during and after the welding process For further information on identifying various types of steel and other metals and for proper procedures for weld ing them we suggest you purchase a copy of New Lessons in Arc Welding See Book Division section Regardless of the type of metal being welded in order to get a quality weld it is important that it be free of oil paint rust or other contaminants Types of Welds Five types of welding joints are Butt Joints Tee Joints Lap Joints Edge Joints and Corner Joints Of these the Butt Joint and Tee Joint are the most common 77 Butt Joint Lap Joint Edge Joint Tee Joint Corner Joint Butt Joints Butt Joints are the most widely used Joints Place two plates side by side leaving 1 16 1 6mm for thin metal to 1 8 3 2mm for heavy metal space between them in order to get deep penetration Tack the plates at both ends otherwise the heat will cause the plates to move apart See drawing TE BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio C f i 0 cre 5 5 51 amp Return to Section TOC Return to Master TOC B 13 right if right handed Point the electrode down in he gap between the two plates keeping the electrodes slightly tilted in the direction of travel 1207 end view
69. d Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to In some c it m n ry to remov fet Ey Ds Tomoye Sariy minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never c
70. e inside of the outlet tube Contaminant on the sealing surface could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers say that it takes only a few grams of dirt to dust an engine Be careful notto damage the sealing area on the tube Wipe both sides of the outlet tube clean Outer edge of the outlet tube Inner edge of the outlet tube If your air cleaner is equipped with a Vacuator Valve Visually check and physically squeeze to make sure the valve is flexible and not inverted damaged or plugged Inspect the Old Filter for Leak Clues Visually inspect the old filter for any signs of leaks A streak of dust on the clean side of the filter is a telltale sign Remove any cause of leaks before installing new filter 4 Inspect New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end whichis the sealing area NEVER install a damaged filter A new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation 5 Insert the New Radial Seal Filter Properly If you re servicing the safety filter this should be seated into position before installing the primary filter Insert the new filter carefully Seat the filter by hand making certain it is
71. e leads at the 1 clock position IMPROPER HANDLING OF THE STATOR CAN RESULT IN SHORTED WINDINGS AND OR LOST OUTPUT Install the end bracket Slide it on and install the two top thru bolts loosely to hold the end bracket for the next step Install the end bracket support BULLDOG 140 LINCOLN B F 47 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 19 CHECKING ROTOR STATOR AIR GAP ROTOR Install the bottom two end bracket thru bolts NOTE The flat washer goes on the top right hand thru bolt for the green ground wire 7 Tap the end bracket with the mallet as neces sary to position it Tighten the bolts to 22 25 ft lbs Alternate tightening in order to pull the assembly together evenly As you tighten look through the brush housing access door and watch the bearing to judge end bracket move ment and alignment Checkthe rotor stator air gap with the long 010 feeler gauge The measurement is taken through the brush holder access door see Figure F 19 Turn the engine with the recoil starter rope slightly so that the rotor iron is up to take the measurement The rotor has two flat sides which are not measured for air gap
72. es Start the engine check the frequency counter At the proper RPM 3700 the counter should read 62 Hz Using the 10mm socket wrench slightly loosen the throttle locking nut See Figure F 8 Using the screwdriver adjust the high speed stop screw until the frequency counter reads 3700 RPM See Figure F 9 Re tighten the throttle locking nut Oscilloscope Method 1 Connect the oscilloscope according to the man ufacturer s instructions At 3700 RPM the waveform should exhibit a period of 16 2 mil liseconds Refer to the NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLY HIGH IDLE NOLOAD in this section of the manual BULLDOG 140 LINCOLN B F 26 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 0 Oo cre 5 5 51 amp Return to Section TOC Return to Master TOC TROUBLESHOOTING REPAIR ree ENGINE THROTTLE ADJUSTMENT TEST ROBIN SUBARU ENGINE continued FIGURE F 8 LOCKING NUT LOCATION THROTTLE LOCKING NUT Qs D 2 Using the 10mm socket wrench slightly loosen 4 Re tighten the throttle locking nut See Figure the throttle locking nut See Figure F 8 F 8 3 Using the screwdriver adjust the high speed stop screw until the waveform period is 16 2 milliseconds See Figure F 9 FIGURE F 9 STOP SCREW LOCATION HIGH SPEED STOP SCREW BU
73. etainer through the slots at the top and bottom of the holder A cable tie works well see Figure 10 This will hold the brushes up so that you can easily install the holder With the needlenose pliers reinstall the red and the black wires to the appropriate termi nals on the brushes The red wire is inboard Slip the holder into position in the generator end bracket Be careful not to loosen the 2 attached wires 11 Reinstall and tighten the 2 screws with the 1 4 nut driver Slowly remove the non metallic retainer from the brush holder and let the brushes snap back against the slip rings Check the wire connections or clearance and tightness Snap the brush holder cover back into posi tion BULLDOG 140 LINCOLN B F 33 F 34 NOTES BULLDOG 140 LINCOLN HE F 34 DOL 19159 01 DOL 01 DOL 01 DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 35 TROUBLESHOOTING AND REPAIR RHEOSTAT REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized
74. eturn to Section TOC Return to Master TOC POSITIVE DC Return to Section TOC Return to Master TOC SINGLE PHASE BRIDGE NEGATIVE DC CIRCUIT CONFIGURATION PROCEDURE The diode bridge is configured as pictured above The individual diodes can be tested using a diode tester or an ohm meter The diodes will read open one way and shorted the other way If any of the diodes read shorted or open in both directions the diode bridge will need to be replaced eio OJO f i fom 3 cre 5 5 amp Return to Section TOC Return to Master TOC BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 17 ROTOR FLASHING CIRCUIT TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for elect
75. for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the con nection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulatio
76. ft and tighten the screw with the small slot head screw driver Check the rheostat knob for proper rotation minimum to maximum Replace the top cover of the control box and tighten the 4 sheet metal screws with the 5 16 nut driver BULLDOG 140 LINCOLN B dnd TROUBLESHOOTING AND REPAIR dud CAPACITOR AND OR DIODE BRIDGE REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in accessing and removing the Capacitor and Diode Bridge for maintenance or replacement of either component MATERIALS NEEDED 3 8 Nutdriver 5 16 Nutdriver Jumper Wire With Alligator Clips On Each End For Discharging The Field Capacitor Slot Head Screwdriver Needlenose Pliers Wiring Diagram Return to Section TOC Return to Master TOC eio OJO
77. fy the current part number by referring to the engine owner s manual RESISTOR Replace or clean engine maintenance parts per the interval outlined in the engine owner s manual OPERATIONAL CLEARANCE Approximately 12 18 of clearance should be around this unit during operation for air flow Reducing this clearance will reduce air flow to the machine causing operational temperatures to increase Possible damage to the machine can result if to much air flow is restricted BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio te 2 olg 5 5 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC GENERATOR WELDER MAINTENANCE STORAGE Store the Bulldog 140 in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT See Figure D 6 It s normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a general overhaul is necessary Remove the brushes and clean the slip rings with fine grit emery paper CAUTION Do not attempt to polish slip rings while engine is running To reinstall the brushes Item 5 press them upward and slide a cable tie Item 6 through the b
78. g machine operation The output of the BULLDOG 140 is dependent on two cri teria the engine RPM and the amount of current in the rotor winding NOTE Unshaded areas of Block Logic Diagram are the subject of discussion BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC ER THEORY OF OPERATION ES FIGURE E 3 ROTOR FIELD FEEDBACK AND AUXILIARY POWER ENGINE MECHANICAL ROTATION CAPACITOR RHEOSTAT ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed to the full wave bridge The DC output of the bridge is fil tered by the field capacitor and controlled by the output rheostat This filtered and controlled feedback voltage is fed to the rotor winding via the brush and slip ring configura tion As the feedback voltage is increased or de creased the outputs of the weld and auxiliary windings are likewise increased or decreased REACTOR OUTPUT TERMINALS 115 AND 230VAC RECEPTACLES When full field voltage is applied to the rotor and the engine is running at high speed 3700 RPM a 230 VAC voltage is developed in the stator auxiliary wind ing This winding is tapped to provide 115 VAC The two voltages 115 and 230 are connected to the appropriate
79. haded areas of Block Logic Diagram are the subject of discussion BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC F TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F Troubleshooting and Repair 2 F 1 How to Use Troubleshooting Guide hn F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting Guide hh hen F 4 F 11 Test PFOCedures a Pee DER F 13 Rotor Voltage Test T ever DRE pax eee ot E Dre eub Phage ee eee F 13 Field Diode Bridge Test isis cheek cR ne Duc DEG Kk iR dea eas F 15 Rotor Flashing Circuit Test 2 hrs F 17 Rotor Resistance Test 2 022942 aka RE Feb MR RR E gh F 21 Engine Throttle Adjustment Test Robin Subaru Engine F 25 Waveltorrri Dlagratms iuuenes F 28 Normal Open Circuit Weld Voltage hn F 28 Normal Open Circuit Voltage Waveform 115VAC Supply F 29 Typical Weld Output Waveform hr F 30 Removal And Replacement Procedures F 31 Brush Removal And Replacement F 31 Rheostat Removal and Replacement
80. he manual BULLDOG 140 LINCOLN B F 48 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i Of dc 9 gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC Fog TROUBLESHOOTING AND REPAIR p RETEST AFTER REPAIR Retest a machine If itis rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components ENGINE OUTPUT No Load RPM Load RPM Maximum Speed 3800 3650 Minimum Speed 3700 3350 WELDER GENERATOR Output Control Field Volts Field Amps Open Circuit Load Volts Load Amps Volts Maximum 37 5 42 5 4 25 6 5 60 66 23 30 136 150 Minimum 55 62 28 36 50 85 AUXILIARY POWER RECEPTACLE OUTPUT 230 Volt Receptacle 115 Volt Receptacle Output Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Volts Control Volts Maximum 240 260 216 240 19 2 22 120 130 108 120 17 20 Current Control Dial set at MAXIMUM or GENERATOR Output values of each receptacle can vary within the range shown BULLDOG 140 LINCOLN B F 50 NOTES BULLDOG 140 LINCOLN HE F 50 DOL 19159 01 DOL 01 DOL 01 DOL 19139 uunje
81. high idle speed when not under load You should not adjust this setting yourself BREAK IN PERIOD The engine will use a greater amount of oil during its break in period Check the oil frequently during break in For more details see the MAINTENANCE section in the engine owner s manual CAUTION During break in the unit should be subjected to moderate loads Before stopping the engine remove all loads and allow the engine to cool sev eral minutes LOW OIL SENSING This engine has a built in sensor which responds to low oil level not pressure When activated the system will shut the engine down The engine will not restart untill sufficient oil is added Check oil level frequently and add oil as required to the full mark on the dipstick DO NOT OVERFILL GENERATOR OPERATION CAUTION sure that any electrical equipment plugged into the generator s AC power receptacles can with stand a 10 voltage and a 4 frequency varia tion Some electronic devices cannot be CTR by the Bulldog 140 Refer A 2 ELECTR in the ection of this manual GENERAL INFORMATION The Bulldog 140 generator is rated at 4000 continu ous watts 5500 surge watts It provides both 120 volt and 240 volt power You can draw up to 20 amps from either side of the 120 volt duplex receptacle but no more than 33 3 amps from both sides at once Up to 16 7 amps can be drawn from the single 240 volt receptacle
82. ing plowshares running the risk of burning through the thin metal Welding Cast Iron When welding on a piece of cold cast iron the tremen dous heat from the arc will be absorbed and distributed rapidly into the cold mass This heating and sudden cooling creates WHITE BRITTLE cast iron in the fusion zone See drawing below hot M A White brittle cast iron This is the reason why welds in cast iron break Actually one piece of the broken cast iron has the entire weld on it and the other piece has no weld on it See drawing below When breaking the weld stays on one piece To overcome this the welding operator has two choic es 1 Preheat the entire casting to 500 1200 F 260 649 C If the cast iron is hot before welding there will be no sudden chilling which creates brittle white cast iron The entire casting will cool slowly 2 Weld 1 2 12 7mm at a time and do not weld at that spot again until the weld is cool This way no large amount of heat is put into the mass Most inexperienced welders will probably use the sec ond method because they have no way of preheating large castings Smaller castings can easily and should be preheated before welding A forge stove fire or the Arc Torch are all excellent means of pre heating When using the 1 2 12 7mm at a time method it is recommended to start 1 2 12 7mm away from the previous bead and weld into the previous bead This is called ba
83. ipstick when checking oil level DO NOT OVERFILL Be sure the fill plug is tight after servicing FUEL Bi Fill the fuel tank with clean fresh regular grade mini mum 87 octane lead free gasoline DO NOT MIX OIL WITH GAS The Bulldog 140 capacity is approxi mately 6 8 gallons 25 74 Liter DO NOT OVERFILL allow room in the fuel tank for fuel expansion SPARK ARRESTER Some federal state or local laws may require gasoline engines to be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this machine does qual ify as a spark arrester Bulldog 140 Typical Fuel Consumption Robin Subaru 10 HP Carb Certified EX 30 31 Gallons Hour 1 16 Liters Hour No Load 3750 RPM 100 R P M AC CC Weld Output 80 Amps 2 25 Volts 53 Gallons Hour 2 02 Liters Hour 70 Gallons Hour 2 65 Liters Hour Auxiliary Power 4000 Watts 120 240 Volts GASOLINE FUEL ONLY BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio E f i gt 5 5 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC d INSTALLATION a Bulldog 140 OUTPUT CONNECTIONS FIGURE A 1 CURRENT CONTROL DIAL WELD OUTPUT
84. istive load and is calculated as WATTS VOLTS X AMPS DRAWN for example a 120 volt device which is rated on its nameplate to draw 2 amps will need 120 VOLTS X 2 AMPS 240 WATTS OF POWER 1 KW 1000 WATTS BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o He 2 a Return to Section TOC Return to Master TOC o 5 o 2 r a OPERATION BS WELDING OPERATION A WARNING GENERAL INFORMATION AN ELECTRIC SHOCK can kill Do not touch electrically live parts electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves The Bulldog 140 has a voltage of up to 66 Volts AC which can shock The Bulldog 140 generator welder can deliver from 70 to 125 amps of continuous welding output current Output can be adjusted by setting the current control dial on the output control panel You can get maximum welding output by setting the dial to 125 AMPS At high current settings like this some output may decrease as the machine is used you are welding for a long time you may need to turn the dial slightly upward to maintain the same results The numbers on the dial correspond to the average amps needed to weld using specific Lincoln welding rods gives you the recommended dial settings based on the thick
85. k attach to the negative terminal To replace the capacitor reattach the leads to their respective terminals 202A Red to positive 201 and 201A Black to negative and tighten the screws securely Snap the capacitor back into the molded plastic holder and slide the holder back into position in the panel Replace the top cover of the control box and tighten down the 4 sheet metal screws with the 3 8 nut driver BULLDOG 140 LINCOLN B F 38 did TROUBLESHOOTING AND REPAIR pes CAPACITOR AND OR DIODE BRIDGE ojo REMOVAL AND REPLACEMENT continued 5 5 FIGURE F 13 FIELD DIODE BRIDGE LOCATION a 3 c Sls 215 200 Red Feild Diode Bridge cc 9 201 Ba ____ ___9 Sjal 2018 ele HE dc PROCEDURE FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT 1 Remove the engine spark plug wire 7 Replace the wires to their appropriate locations 2 With the 3 8 nut driver remove the 8 sheet onhe HOW diode metal screws that hold the top cover to the con Lead 200 attached to the positive terminal trol box Remove the top cover Depending on the bridge used this corner may be 3 With the 3 8 nut driver and wrench remove the beveled and or marked with sign 6 screws that hold the control panel in place 2 Lead 201 and 201B are piggy backed on the neg
86. l 1 888 935 3877 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 0 c 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC rn TROUBLESHOOTING AND REPAIR ii Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S The welding arc is cold engine runs normally 3700 RPM no load Auxiliary power is func tioning normally WELDING PROBLEMS The 1 Check for loose or faulty con nections at the weld output terminals and welding cable con nections The welding cable may be too long or coiled causing an exces sive voltage drop RECOMMENDED COURSE OF ACTION Check for the correct open cir cuit voltage OCV at the welder output terminals 66 15 normal If the correct voltage is present at the output terminals check for loose connections on the heavy current carrying leads inside the BULLDOG 140 See the Wiring Diagram If the OCV is low at the welder output terminals perform Engine Throttle Adjustment Check for shorted or grounded windings in the reactor L1 and also in the main stator See the Wiring Diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Linc
87. ld of smoke like gas around the arc to keep oxygen and nitrogen in the air away from the molten metal and provides a flux for the molten pool The flux picks up impurities and forms a protective slag The principle differences between the various types of elec trodes are in their coatings By varying the coating it is possible to greatly alter the operating characteristics of electrodes By understanding the differences in the various coatings you will gain a better understanding of selecting the best electrode for the job you have at hand In selecting an electrode you should consider 1 The type of deposit you want e g mild steel stain less low alloy hardfacing 2 The thickness of the plate you want to weld 3 The position it must be welded in downhand out of position 4 The surface condition of the metal to be welded 5 Your ability to handle and obtain the desired elec trode Four simple manipulations are of prime importance Without complete mastery of these four further attempts at welding are futile With complete mastery of the four welding will be easy 1 The Correct Welding Position Illustrated is the correct welding position for right hand ed people For left handed people it is opposite Whenever possible weld from left to right if right handed This enables you to see clearly what you are doing Hold the electrode at a slight angle as shown in Figure 5 Figure 5 _ gt 15 20
88. le until resis tance is felt 4 Pull the cord rapidly FOR BEST ENGINE STARTING Always use fresh gasoline and be sure the filter is clean and properly maintained Do not pull the recoil starter with the If you use an alternate fuel tank or supply be sure to choke in the CHOKE position more than one time Repeated pulls on a install an in line fuel filter choked engine will flood the carburetor If the engine will not start see the TROU BLESHOOTING section of this or the engine owner s manual BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E EB i 2 0 9 gt 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC Ep OPERATION STOPPING THE ENGINE 1 Remove all welding and generator power loads and let the engine cool by running it for several minutes 2 Stop the engine by placing the ON OFF switch in the OFF O position 3 Close the fuel shutoff valve A WARNING Close the fuel valve when the machine is trans ported to prevent fuel leakage from the carburetor For long periods of storage turn off the fuel shut off valve and let the engine run until there is no more fuel in the line Use a fuel additive such as Sta Bil to minimize fuel gum deposits RUNNING THE ENGINE The engine is set at the factory to run at
89. lip rings Place the other probe on any good unpainted ground Use the ground stud or the rotor thru bolt C Check the resistance It should read very high at least 5 megohm 500 000 ohms If the resistance checks meet the specifications then the rotor is okay BULLDOG 140 LINCOLN B F 22 Fes TROUBLESHOOTING AND REPAIR Fea ROTOR RESISTANCE TEST continued FIGURE 6 BRUSHES RETAINED WITH CABLE TIE Return to Section TOC Return to Master TOC CABLE TIE BRUSHES Return to Section TOC Return to Master TOC 9 Reinstall the brush holder assembly after the test Depress the spring loaded brushes into the holder and slip a suitable non metallic fair ly stiff retainer through the slots at the top and bottom of the holder A cable tie works well see Figure F 6 This will hold the brushes up so that you can easily install the holder eio OJO f i cre 5 5 amp 10 Slip the holder into position in the generator end bracket Be careful not to loosen the 2 attached wires 11 Reinstall and tighten the 2 screws with the 1 4 nutdriver 12 Slowly remove the non metallic retainer from the brush holder and let the brushes snap back against the slip rings 13 Snap the brush holder cover back into posi tion Return to Section TOC Return to Master TOC BULLDOG 140 LINCOLN B F 24 NOTES BULLDOG 140 LINCOLN HE
90. loves FUMES AND GASES can be I2 dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone 2 WELDING SPARKS cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 4 Wear eye ear and body protection RZ ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure 9 des Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or service this equipment ui OPERATION B2 GENERAL DESCRIPTION The Bulldog 140 is a generator welder designed for home use and other non commercial applications As a generator it can supply up to 4 000 continuous watts or 5 500 surge watts of 120 240 volt single phase AC power As a welder it provides 125 amps of AC constant current for welding with AC stick electrodes A single dial provides continuous adjustment of welding output The machine is lightweight portable and can be lifted by two people The Lincoln warranty covers the Bulldog 140 exclud ing the engine for 3 years from the date of purchase The engine is covered by the engine manufacturer s warranty policy RE
91. m burn through Follow these simple rules 1 Hold avery short arc This together with the prop er travel speed will eliminate burn through 2 Use 1 8 3 2mm or 3 32 2 5mm AWS 6011 3 Use low amperage 75 A for 1 8 3 2mm elec trode 70 A for 3 32 2 5mm electrode OPERATION B 15 4 Move rapidly enough to stay ahead of the molten slag A whipping technique may be used to further minimize burn through 5 If you have choice use lap joints rather than fillets or butts the double thickness effect of a lap joint makes it much easier to weld without burning through Hardfacing To Reduce Wear There are several kinds of wear The two most often encountered are 1 Metal to Ground Wear Plowshares bulldozer blades buckets cultivator shares and other metal parts moving in the soil 2 Metal to Metal Wear Trunnions shafts rollers and idlers crane and mine car wheels etc Each of these types of wear demands a different kind of hardfacing electrode When applying the proper electrode the service life of the part will in most cases be more than double For instance hardfacing of plowshares results in 3 5 times more acreage plowed How to Hardface the Sharp Edge Metal to Ground Wear 1 Grind the share approximately one inch along the edge so the metal is bright and clean 2 Place the share on an incline of approximately 20 30 The easiest way to do this is to put one end of
92. n through on very thin plate 30 40 6 Watch the molten metal carefully The important thing is to continue lowering the entire arm as the weld is made so the angle of the electrode does not change Move the electrode fast enough so that the slag does not catch up with the arc BULLDOG 140 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt 2 0 olg 5 5 Dllo amp Return to Section TOC Return to Master TOC B 15 Overhead Welding Various techniques are used for overhead welding However in the interest of simplicity for the inexperi enced welder the following technique will probably take care of his needs for overhead welding 1 Use 1 8 3 2mm 90 105 A or 3 32 2 5mm 70 A AWS 6011 electrode on AC 2 Put the electrode in he holder so it sticks straight out 3 Hold the electrode at an angle approximately 30 off vertical both seen from the side and seen from end See drawing below Side View End View i 30 30 It is important to hold a VERY SHORT arc Along arc will result in falling molten metal a short arc will make the metal stay If necessary and this is dictated by the appearance of the molten puddle a slight back and forth whipping technique may be used to prevent dripping Welding Sheet Metal Welding sheet metal presents an additional proble
93. n to Master TOC F 10 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S Engine will not stop running Engine runs erratically or stops run ning Engine sputters but will not start ENGINE PROBLEMS The piercing stop switch may not be contacting the spark plug Make certain that the pointed end of the lever firmly contacts the spark plug tip Check the spark plug boot and wire for loose or faulty connec tion The spark plug may be faulty Replace The fuel and air mixture may be out of adjustment Consult Robin Subaru owner s manual The fuel supply may be con taminated with water The spark plug may be faulty The fuel supply may be contami nated with water The air filter may be clogged Replace The fuel and air mixture may be out of adjustment TROUBLESHOOTING AND REPAIR F 10 RECOMMENDED COURSE OF ACTION 1 Consult Be sure the piercing stop switch is securely mounted to the engine The engine may require service to the head or carburetor The fuel pump may be faulty Consult Robin Subaru Robin Subaru owner s manual A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Cal
94. nch 7 16 Open or Box End Wrench 3 4 Socket or Box End Wrench 1 2 Socket or Box End Wrench Needlenose Pliers Diagonal Cutters Torque Wrench ft Ibs Babbitt Leather or Wooden Mallet Volt Ohmmeter 12 long Feeler Gauge 010 INSTRUCTIONS For stator removal only follow steps 1 8 under STATOR REMOVAL PROCEDURE For_rotor removal follow the STATOR REMOVAL PROCEDURE ROTOR REMOVAL PROCEDURE BULLDOG 140 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i cre 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC in TROUBLESHOOTING AND REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE 14 GENERATOR AND ENGINE LOCATION GENERATOR PROCEDURE 1 Remove control panel cove by removing the 20 screws with a 3 8 nutdriver 2 Remove the right case side by removing the 5 Screws using a 3 8 nutdriver 3 Make sure the run off switch on the rear of the engine is in the off position Remove the gas line from the engine by closing the gas valve and pinching open the clip using a pair of needlenose pliers Label and remove all of the leads that are com ing up from the center hole in the control box from the stator See Wiring Diagram The engine can be removed by unbolting the two 9 16 anchor bolts from the engine side and the t
95. ns Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applica tions 1 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment BULLDOG 140 LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Accessories a beta ica es danish wise aad wretch lan te Section C gt gt Section D Theory of Operation dues ewe ee ee Erw ui Section E Troubleshooting and Repair Section F Electrical Diagrams i eee i ee ee Section G Parts Martial al acd wave uated ca da e d Wee ale ceca aceite 615 BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 t Return to Master TOC A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation A 1 Technical Specifications ss s siss aiia naad i emaa eee A
96. ntact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 0 c 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC rh TROUBLESHOOTING AND REPAIR r Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS No weld output and no auxiliary out 1 The generator brushes 1 Perform the Rotor Voltage Main J put engine runs normally worn or faulty See the tenance Section this manual 2 If the rotor voltage is zero to 3 or contact your local Lincoln Electric Authorized Flald ser VOS check the flywheel alters vice Facility nator and associated wires 200A 202 and 202A for conti The voltage from lead 200A to ground should be at least 18 to 21 VDC at 3700 RPM Normal voltage is 37 5 42 5VDC If the voltage is low or missing the flywheel alterna tor may be faulty See the Wiring Diagram Check diode 03 8 lead 202C Check lead 2018 green for continuity zero ohms to ground See wiring diagram The field capacitor C1 or bridge D2 may be faulty Test or replace Test the rheostat R1 No
97. oil the electrode lead around your body 14 Do not put your hands near the engine fan 2 d 3 Do not place your body between the electrode and Do not attempt to override the governor or idler by pushing on the throttle control rods M while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal st
98. oln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 BULLDOG 140 LINCOLN B F 12 NOTES BULLDOG 140 LINCOLN HE F 12 DOL 19159 01 DOL 01 DOL 01 DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 13 ROTOR VOLTAGE TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct DC voltage is being applied to the Rotor at maximum engine speed 3700 RPM This information will aid the techni
99. oltage is correct the generator field is okay Replace the top cover on the control box Tighten the 4 sheet metal screws with the 3 8 nut driver BULLDOG 140 LINCOLN F 14 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 15 FIELD DIODE BRIDGE TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will test the Diode Bridge for any faulty diodes and will help determine the configuration for the Bridge MATERIALS NEEDED Volt Ohmmeter Diode Tester BULLDOG 140 LINCOLN B F 15 TROUBLESHOOTING AND REPAIR F5 TROUBLESHOOTING AND REPAIR 8 FIELD DIODE BRIDGE TEST continued FIGURE F 2 DIODE BRIDGE CIRCUIT CONFIGURATION R
100. on the approximation of the laws of the Member States relating to electromagnetic compatibility 2004 108 EC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other ca
101. onnected at machine 115 VAC receptacle eio te 2 olg 5 5 amp ojo o SCOPE SETTINGS 5 5 50V Dw Horizontal Sweep 5 ms Div o Coupling DC Trigger Internal 5 dc BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio EC te 2 olg fom 3 cre 5 5 amp Return to Section TOC Return to Master TOC TROUBLESHOOTING REPAIR r5 TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED 50V O volts 20 volts 5ms MACHINE LOADED TO 125 AMPS AT 23 VAC This is the typical AC output voltage generated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio
102. oosen the screw that holds the knob to the rheostat shaft The shaft has a flat for locating the knob at reassembly 4 With a 9 16 open or box end wrench remove the nut that holds the rheostat to the control panel Support the rheostat with your hand as you turn the nut There is a shake proof wash er under the nut 5 Pull the rheostat back out of the control panel and lay it out on its wires to loosen the nuts that hold them 6 With the 5 16 open or box end wrench remove the brass nuts from the wire terminals Support the terminals as you turn the wrench to avoid ripping the terminals from their foundations Note the wire locations for reassembly 12 NOTE The brass screws are double nutted with a shake proof star washer under the screw head To reinstall the rheostat replace each of the brass screws Place a shake proof star wash er under the head insert the screw into the rheostat and tighten down one nut Replace the appropriate wires and tighten down the second nut Again support the terminals as you turn the wrench to avoid ripping the termi nals from their foundations Reassemble the rheostat to the front of the control panel Line up the locating tab on the rheostat with the slot on the control panel hole Reassemble the shake proof star washer and nut and tighten securely with the 9 16 wrench Locate the flat spot on the shaft line up the knob locking screw push the knob onto the sha
103. ously variable from 70 to 125 amps AC The Bulldog 140 can weld with all 3 32 and most 1 8 inch diameter Lincoln AC electrodes BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 Oo 5 5 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC B 3 L IMITATIONS The Bulldog 140 is not recommended for any processes besides those that are normally per formed using stick welding SMAW procedures The Bulldog 140 is not recommended for pipe thawing During welding generator power is limited to 100 watts and output voltages can drop from 120 to 80 volts and 240 to 160 volts Therefore DO NOT OPERATE ANY SENSITIVE ELECTRICAL EQUIP MENT WHILE YOU ARE WELDING CONTROLS AND SETTINGS All welder generator controls are located on the Output Control Panel Gasoline engine controls are mounted on the engine See Figure B 1 and the figures in engine operation section WELDER GENERATOR CONTROLS See Figure B 1 for the location of the following fea tu 1 res CURRENT CONTROL DIAL Adjusts continuous current output The amperages on the dial corre spond to the approximate amperages needed for specific Lincoln welding electrodes 20 AMP CIRCUIT BREAKER Provide separate overload current protection for the 120 Volt and 240 Volt Receptacles OPERATION 3
104. p Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES OPTIONS ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options accessories are available for your Bulldog 140 from your local Lincoln Distributor Accessory Kit K875 Includes the following 20 Ft 6 1m 6 welding cable with lug 15 Ft 4 6 6 work cable with lugs 200 amp electrode holder Light duty work clamp Sample electrode pack Welding Gloves Helmet Chipping Hammer and Brush Undercarriage K2722 1 A two wheeled hand mov able undercarriage is available for field installation Canvas Covers K2804 1 To protect the Bulldog 140 when not in use Made from attractive red canvas which is flame retardant mildew resistant and water repellent Rotor Removal Kit S20925 A service kit with thru and impact bolts for removing the generator rotor from the tapered engine crankshaft K2819 1 Lift Bail Kit Easily installed kit for lifting the machine with a fixed lifting point BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 t Return to Master TOC D 1 gt TABLE OF CONTENTS MAINTENANCE SECTION 7 Maintenance v veda peepee ONES LI SI c SUE D 1 Safety INStructions secet eue dies Henne ees Pa clerk uie Blake SE rid aca puo Pack ED RR
105. personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop CAUTION Do not use petroleum solvents such as kerosene to clean the air cleaner They may cause deterio ration of the air cleaner DO NOT OIL THE AIR CLEANER OR USE PRESSURIZED AIR TO CLEAN OR DRY THE AIR CLEANER To service the pre cleaner 1 Wash in liquid detergent and water 2 Squeeze dry in a clean cloth 3 Saturate in clean engine oil 4 Squeeze in a clean absorbent cloth to remove all excess oil CLEAN ENGINE Remove dirt and debris with a cloth or a brush Do not clean with a forceful spray of water Water might contaminate the fuel system CAUTION Periodically clean the muffler area to remove com bustible debris Clean Finger Guard Area If your Bulldog 140 is equipped with an engine that has a finger guard you should clean it as often as needed to remove dirt or debris that may collect on the fin areas A dirty finger guard can result in overheating and damaging the engine See Figure D 2 FIGURE D 2 CLEAN AREA S amp S 1 FINGER GUARD AREA CLEAN COOLING SYSTEM See Figure D 3 Clean the internal cooling fins and surfaces to prevent over speeding overheating and engine damage Clean every 100 operating hours or as often as necessary FIGURE D 3 CLEAN COOLING SY
106. r Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Gasoline Engines ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND E MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric an
107. re welding Avoid allowing the welding circuit to pass through hinges bearings electronic compo nents or similar devices that can be damaged ELECTRODE HOLDER WELDING MACHINE AC OR DC POWER SOURCE AND CONTROLS ELECTRODE WORK CABLE ELECTRODE CABLE 7 FIGURE 3 The welding circuit for Stick shielded metal arc welding OPERATION B 10 The electric arc is made between the work and the tip end of a small metal wire the electrode which is clamped in a holder that is held by the welder A gap is made in the welding circuit see Figure 3 by holding the tip of the electrode 1 16 1 8 1 6 3 2mm away from the work or base metal being welded The elec tric arc is established in this gap and is held and moved along the joint to be welded melting the metal as it is moved Arc welding is a manual skill requiring a steady hand good physical condition and good eyesight The oper ator controls the welding arc and therefore the quali ty of the weld made What Happens in the Arc Figure 4 illustrates the action that takes place in the electric arc It closely resembles what is actually seen during welding The arc stream is seen in the middle of the picture This is the electric arc created by the electric current flowing through the space between the end of the elec trode and the work The temperature of this arc is about 6000 F 3300 C which is more than enough to melt metal The
108. rical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the Engine Magneto is supplying the proper flashing current to the Rotor MATERIALS NEEDED Volt Ohmmeter 3 8 Nutdriver DC Ammeter Wiring Diagram BULLDOG 140 LINCOLN B F 17 TROUBLESHOOTING AND REPAIR ce TROUBLESHOOTING AND REPAIR p ROTOR FLASHING CIRCUIT TEST continued ojo e e 5 5 FIGURE F 3 BRUSH HOLDER LEADS 201 2028 212 c 515 22 2H cs Bs e ve 201A SLIP Z e E RINGS Fie 5 8 ES 2 g 2 202 JE 77 ala dc PROCEDURE 1 With the 3 8 nutdriver remove the 20 sheet 3 Connect the negative lead of the DC amme metal screws that hold the top cover to the con ter to lead 201A and the positive lead to the trol box Remove the top cover brush holder 2 Locate and remove lead 201A from the brush 4 Remove lead 77 from field diode bridge rectifier holder See Figure F 3 for location D2 See Figure F 4 Electrically isolate the lead ojo FIGURE DIODE BRIDGE LEAD ASSIGNMENTS 5 5 Bis 200 pos 200C 3 e 7 c 201 9 201 OJO i cre 5 5 amp
109. rmal resistance is 3 3 ohms See the Rheostat Removal and The rotor may be faulty Per form the Rotor Resistance Test 7 Perform Flashing Circuit Test A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 2 olg 9 1 5 2 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC ru TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS No weld output auxiliary power 1 Check the open circuit voltage 1 Check continuity zero ohms of 230 115 VAC operates normally OCV at the welder output termi lead W1A black from output engine runs normally nals If OCV is okay go to Step terminal to reactor L1 See 2 below the Wiring Diagram If OCV is not present at the welder 2 Check continuity zero ohms of output terminals contact your lead W2 black from output ter local Lincoln Electric Authorized minal to stator winding See the Field Service Facility Wiring Diagram
110. ructures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 i SAFETY ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing
111. rush hold er tabs as shown in figure D 6 Install the brush hold er Item 1 into the bearing end bracket Item 3 and secure with the screws Item 4 previously removed Remove the cable tie and the brushes will seat onto the slip rings and replace bearing bracket end cover Item 2 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 tight NOTE Lincoln offers a rotor removal kit for any ser vice which requires removal of the rotor from the engine See the ACCESSORIES section for further details Removal of engine generator assembly from the cra dle can be achieved as follows Remove the two 5 16 18 hex head cap screws from the engine block via the access hole located in the cradle cross support channel Leave all other engine mountings intact Remove the two hex nuts from the isolator thread ed posts at the stator support bracket located oppo site the engine Leave all other stator mountings intact e With a jib hoist or crane lift the unit upward and remove loose cradle from engine generator assem bly FIGURE 0 6 BRUSH REMOVAL AND REPLACEMENT gt BRUSH BRUSH HOLDER ASSEMBLY BEARING BRACKET END COVER ENGINE END BRACKET 2 SCREWS 2 BRUSHES CABLE TIE BULLDOG 140
112. s trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la
113. s along with the nuts With the 7 16 socket and 7 16 end wrench remove the 4 thru bolts for the generator assembly See Figure F 17 Note the green grounding wire on the top right hand bolt It has a flat washer All 4 bolts have a split ring lock washer under the head and a shake proof star washer on the nut side The bolts must point toward the engine for reassembly 15 Lift up the stator and slide out the support bracket The engine will now rest on the 2 X 4 With the babbitt leather wooden mallet tap off the end bracket Alternate sides as you tap watch the bearing to judge the amount of movement you re getting Once the end bracket is off carefully pull off the stator IMPROPER HANDLING OF THE STATOR CAN RESULT IN SHORTED WIND INGS AND OR LOST OUTPUT BULLDOG 140 LINCOLN B F 46 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 47 TROUBLESHOOTING AND REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 18 ROTOR WITH STATOR REMOVED ROTOR THRU BOLT ROTOR REMOVAL PROCEDURE 1 To remove the rotor double check that the spark plug wire is disconnected You will be turning the rotor during this procedure and this could accidentally cause engine kickback With an impact wrench
114. ses it could involve construction of an electromagnetic screen enclosing the power source and the work com plete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equip ment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or o
115. st familiar welding process known A coated ELECTRODE the weld rod is clamped into an ELECTRODE HOLDER an insulat ed clamping device which in turn connects to the ELECTRODE CABLE a heavy wire The WORK the metal piece to be welded is connected to the WORK CABLE a heavy wire which contains the WORK CLAMP Quality Lincoln cables use many fine copper wires with a very flexible insulating covering for the electrode and work cables When properly connected to the OUTPUT STUDS of a high current power source the electrode melts and bonds the metal being repaired See Cable Installation section for proper cable connection to a Power Arc The Power Arc provides excellent weld output charac teristics when used in combination with Lincoln AC electrodes Other AC electrodes may also be used Follow the settings listed in Table B 2 Welding Application Guide and the Electrode Selection Guide found on the nameplate of the machine Learning To Stick Weld The serviceability of a product or structure utiliz ing this type of information is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fab rication methods and service requirements BULLDOG 140 LINCOLN B Return to Section
116. st the choke to prevent car buretor flooding The recoil starter may not be engaged with the engine gently hit the blower housing and or pull the rope to its fully extended position and rapidly wiggle it Repeat until the clutch engages with the engine shaft and resis tance is felt Low oil and engine low oil shut down protection will not allow unit to start Light in ON OFF Switch will flash when engine is cranked Engines equipped with low oil shutdown protection only TROUBLESHOOTING AND REPAIR F 9 RECOMMENDED COURSE OF ACTION Check the fuel line for breaks or obstructions Replace the fuel filter DO NOT RUN THE EN GINE WITHOUT AN IN LINE FUEL FILTER The spark plug may be faulty Replace Service the engine as outlined the Maintenance Section of this manual The engine magneto may be faulty Consult Briggs amp Stratton owner s manual The engine may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 2 olg 9 1 5 5 Dllo amp Return to Section TOC Return to Master TOC Retur
117. sure the angle of the electrode is right and be sure to use both hands 2 When you can strike an arc without sticking prac tice the correct arc length Learn to distinguish it by its sound 3 When you are sure that you can hold a short crack ling arc start moving Look at the molten puddle constantly and look for the ridge where the metal solidifies 4 Run beads on a flat plate Run them parallel to the top edge the edge farthest away from you This gives you practice in running straight welds and also it gives you an easy way to check your progress The 10th weld will look considerably bet ter than the first weld By constantly checking on your mistakes and your progress welding will soon be a routine matter Common Metals Most metals found around the farm or small shop are low carbon steel sometimes referred to as mild steel Typical items made with this type of steel include most sheet metal plate pipe and rolled shapes such as channels angle irons and I beams This type of steel can usually be easily welded without special precau tions Some steel however contains higher carbon Typical applications include wear plates axles con necting rods shafts plowshares and scraper blades OPERATION B 12 These higher carbon steels can be welded successful ly in most cases however care must be taken to follow proper procedures including preheating the metal to be welded and in some cases carefully
118. tection transient protection and additional loading is recom mended for 100 fail safe oper ation DO NOT RUN THESE DEVICES WITHOUT ADDI TIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large drills well pumps grinders small refrigerators weed and hedge trimmers current inrush for starting See Table 1 POWER APPLICATIONS in the OPERATION section of this manual for required starting wattages Some synchronous motors may be frequency sensi tive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV sets complicated electrical equipment An inductive type line condition er along with transient and surge protection is required and liabili ties still exist DO NOT USE THESE DEVICES WITHA Bulldog 140 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the Bulldog 140 BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC 5 o 2 t Return to Master TOC B 1 TABLE OF CONTENTS OPERATION SECTION E Operation be e EE LE EUN SII DE UE AE i SIUE B 1 Safety Instructions 2 General Description 2 23 uus eek edad ek 2
119. ter TOC Return to Section TOC eio te 2 Of dc 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 22 TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST continued FIGURE F 5 LOCATION OF ROTOR SLIP RINGS BRUSH HOLDER ASSEMBLY REMOVED SLIP RINGS PROCEDURE Conduct the test with the gasoline engine OFF Remove the spark plug wire to prevent acci dental engine kickback or starting Isolate the rotor electrically by removing the generator brushes Refer to Figure F 5 as you perform the remaining steps Open the brush holder assembly cover Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fingernail The cover will drop open on its bottom hinge With the 1 4 nut driver remove the 2 screws that hold the brush holder assembly in place Slide the brush holder assembly out and lay it aside held by the 2 wires attached 7 Measure the resistance across the rotor slip rings A Setthe ohmmeter on the low scale X1 B Place one meter probe on one of the rotor slip rings Place the other probe on the other slip ring C Check the resistance across the slip rings It should read 7 9 ohms 8 Measure the resistance to ground A Set the ohmmeter on the high scale X100 000 B Place one probe on either of the s
120. that hold the brush holder assembly in place With the needlenose pliers gently remove the black and the red wires Set the brush holder aside Pull the wires up into the control box Pull apart the molex coupling for the engine fly wheel alternator This is the single wire on the left side of the machine running from the engine to the stator Disconnect lead W1 Black that connects to the reactor lead Replace the nut split ring lock washer and flat washer finger tight on the bolt for reassembly Slide the control panel and box assembly out of the machine cradle Carefully pull the wire leads down through the box as you remove it Note that the reactor is loose inside the box and may slide around BULLDOG 140 LINCOLN F 45 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 46 12 13 TROUBLESHOOTING AND REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE 17 STATOR END BRACKET SUPPORT AND THRU BOLTS THRU BOLTS SUPPORT Slide a short length of 2 X 4 under the engine to support it when the stator is removed With the 1 2 socket wrench remove the 2 nuts that hold the stator end bracket support See Figure F 17 for location There are 2 split ring lock washers and 2 flat washer
121. the rheostat R1 Normal resistance is 3 3 ohm See the Rheostat Removal and Replacement Procedure The rotor may be faulty Per form the Rotor Resistance The engine RPM may be low Perform the Engine Throttle Adjustment Test If engine idle RPM is okay the engine may have lost horse power and be in need of major repair Perform Field Diode Test worn See the Sectionlot this manual or contact your local Lincoln Electric Authorized Field Service Facility A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt olg 9 1 5 5 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC F 9 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S Engine will not start ENGINE PROBLEMS Make sure the ON OFF switch is in the ON position Check spark plug boot and wire for loose or faulty connection Make sure that the fuel shutoff valve is in the ON position Make certain that the engine has adequate fuel and oil Adju
122. the ridge where the molten puddle solidi fies indicates correct welding speed The ridge should be approximately 3 8 9 5mm behind the electrode Ridge where puddle Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal IMPORTANT It is not generally necessary to weave the arc forward backward or sideways Weld along at a steady pace and you will have an easier time NOTE When welding on thin plate you will find that you have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly to ensure fusion and penetration BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt 0 olg 5 2 amp Return to Section TOC Return to Master TOC B 12 PRACTICE The best way of getting practice in the four skills that enable you to maintain 1 Correct Welding Position 2 Correct Way to Strike An Arc 3 Correct Arc Length 4 Correct Welding Speed is to spend a little more time on the following exercise Use the following Mild Steel Plate Electrode 3 16 4 8mm or heavier 1 8 3 2mm AWS 6011 Fleetweld 180 Current Setting 90 125 Amps AC Do the following 1 Learn to strike the arc by scratching the electrode over the plate Be
123. ther activities are to be carried out BULLDOG 140 LINCOLN B Return to Master TOC Return to Master TOC o 5 o 2 tc Return to Master TOC vi SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except
124. tor windings See the Wiring Dia gram Check for loose or faulty plug at power receptacle Make sure lead 5 white is grounded to the machine frame zero ohms Check for an open or grounded auxiliary winding in the stator 6 yellow to 3 black See the Wiring Diagram Return to Section TOC Return to Master TOC eio OJO f gt 0 c 9 1 5 5 Dllo amp c A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 0 c 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC ini TROUBLESHOOTING AND REPAIR a Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Low weld output and low auxiliary 1 The generator brushes may 1 Perform the Rotor Voltage If the rotor voltage is low the field capacitor C1 or bridge D2 may be faulty Test or 2 The engine RPM may be low replace Check
125. ts and numbers OIL Check the oil level after every 5 hours of operation or BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 20 hours of operation Then under normal operating conditions change the oil after every 100 hours or once every 6 months whichever occurs first If the engine is operated under heavy load or in high ambient temperatures change the oil every 25 hours Drain the oil from the drain plug located on either side of the engine bottom as shown in Figure D 1 Refill through the oil fill plug until the oil reaches the top of the fill hole Use the grade and viscosity recommend ed in the engine owner s manual FIGURE D 1 OIL DRAIN AND REFILL LOCATION 1 OIL DRAIN PLUG 2 OIL FILL PLUG 3 OIL LEVEL BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO E f i 0 gt 5 2 amp c Return to Section TOC Return to Master TOC m MAINTENANCE p FUEL At the end of each day s use refill the fuel tank to minimize moisture condensa tion and dirt contamination in the fuel line ENGINE ADJUSTMENTS WARNING OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM no load DO NOT tamper with the governor components or setting or make any other adjust ments to increase the maximum speed Severe
126. ture or chemical form Low hydrogen electrodes offer these benefits outstanding crack resistance lowest porosity on sul phur bearing steels and X ray quality deposit capabil ity Thus they are the first choice when welding prob lem steels E7018 can be used in all positions with Motion below recommended for the first pass on vertical up welds NEVER use a whipping technique or a long arc with these electrodes ALWAYS fill craters by drawing electrode away slowly ALWAYS keep these electrodes dry Electrodes when not used with in a few hours after a container is opened must be stored in heated cabinets Motions BULLDOG 140 LINCOLN B B 18 NOTES BULLDOG 140 LINCOLN HE B 18 DOL 19159 01 DOL 01 DOL 01 DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 E TABLE OF CONTENTS ACCESSORIES SECTION E ln udis ie rs MM I Mee Gee Ree I ME id C 1 Options ACCESSONIES gt seed rica Eee ee ee Rupee Per Rb dS 2 Return to Master TOC Return to Master TOC o 5 o 2 t Return to Master TOC BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 2 0 5 2 am
127. until rotor pops off of tapered engine crank If impact wrench is unavailable restrain rotor and tighten bolt with socket wrench until rotor pops off A slight tap of the impact bolt with a babbitt hammer may be required Return to Section TOC Return to Master TOC 13 Replace rotor onto shaft Be certain to Tighten rotor to 22 25 ft Ibs Check air gap between stator and rotor Gap must be 020 MIN Tighten 4 long bracket bolts to 4 5 5 5 ft Ibs Rewire unit as detailed in diagram past ed onto inside of roof Tighten all hardware and insulate all leads accordingly Return to Section TOC Return to Master TOC eio OJO f i c fom 3 cre 5 5 Dllo amp c Return to Section TOC Return to Master TOC BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 0 olg 5 5 Dllo amp Return to Section TOC Return to Master TOC F 45 TROUBLESHOOTING AND REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 16 OUTPUT LEAD LOCATION TIE WRAP STATOR REMOVAL PROCEDURE 1 Remove the 4 1 2 Remove engine spark plug wire to prevent acci dental kickback or starting With the 5 16 nutdriver remove the 4 sheet metal screws that hold the top cover to the con trol box
128. wo 1 2 bolts from the generator side Pull the engine generator from the right side of the welder BULLDOG 140 LINCOLN B F 42 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f gt 0 olg cre 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC noe TROUBLESHOOTING AND REPAIR pus STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 15 GENERATOR COMPONENTS THRU BOLT BRUSH ASSEMBLY STATOR LAMINATION ASSEMBLY BEARING BRACKET END BRACKET END COVER MACHINING 6 Remove the brush assembly from the slip ring 10 Install the 7 70 long thru bolt supplied with the end bracket kit into the rotor THREAD BOLT UNTIL TIGHT 7 Remove the 4 long HHCS and hardware ENGINE CRANKSHAFT along with the slip ring end bracket 11 Install the supplied left hand impact bolt counter clockwise into the rotor shaft Continue to tighten impact bolt until interfer ence with thru bolt is felt 8 Carefully remove the stator from the engine end bracket and cradle IMPROPER HANDLING OF THE STATOR CAN RESULT IN SHORTED WINDINGS AND OR LOST OUTPUT 9 Remove the rotor thru bolt located at the bear ing end of the rotor BULLDOG 140 LINCOLN B TROUBLESHOOTING REPAIR dpa STATOR ROTOR REMOVAL AND REPLACEMENT continued 12 If impact wrench is available rapidly torque impact bolt
129. y cycle applying to currents above 100 Amps 2 Duty cycle is based on a ten minute od The welder can be loaded to 125 Amps for three minutes out of every ten minute period or to 100 Amps for six min utes out of every ten minute period CONTROL FUNCTION OPERATION Current Control Dial Provides welding current adjustment from 70 through 125 Amps To obtain maximum weld output turn the Current Control Dial to 125 Amps for either a cold or hot engine As the machine is used some welding voltage may decrease at high current settings If you are weld ing for long periods of time the dial may need to be slightly turned upward to provide the same welding results as when the machine was cold The numbers listed on the dial correspond to the aver age amperage needed to weld specific Lincoln rods Refer to Table B 2 Welding Application Guide and Electrode Selection Guide listed on the machine nameplate for proper current and electrode settings BULLDOG 140 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 olg 9 gt 5 5 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC E OPERATION E WELDING GUIDELINES TABLE B 2 WELDING APPLICATIONS ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Size Setting FLEETWELD 37 90 amps AWS E6013 1 8
130. ycle 50 RPM 287 Recoil start Code air cooled at no load Manual choke 1 1 qts 1 0 1 11518 OHC gasoline Bore x Stroke 10 HP 2 95 x 2 56 3600 RPM 76mm x 65mm Aluminum Block with Cast Iron Sleeve RATED OUTPUT WELDER Duty Cycle Amps AC Volts at Rated Amperes 3096 Duty Cycle 125 Amps AC Constant Current 20 VAC 6096 Duty Cycle 100 Amps AC Constant Current 25 VAC OUTPUT WELDER AND GENERATOR Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power 70 140 Amps AC 66 VAC Max 4000 Continuous Watts 5500 Surge Watts PHYSICAL DIMENSIONS Height Width Depth 25 47 in 21 12 in 31 48 in 646 mm 536 45 mm 799 59 mm BULLDOG 140 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 0 gt 5 5 Dllo amp Return to Section TOC Return to Master TOC Aa INSTALLATION SAFETY PRECAUTIONS Read this entire installation section before you start installation A WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing

Lincoln Electric SVM208-A Portable Generator User Manual

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