Lincoln Electric BULLDOG SVM208-A manual

SVM208-A January , 201 1 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRE[...]

BULLDOG® 140 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _______________________[...]

ARC RA YS 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 open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of [...]

BULLDOG® 140 SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with [...]

SAFETY iv iv BULLDOG® 140 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. [...]

SAFETY Electromagnetic Compatibility (EMC) Confor mance P roducts displaying the CE mark are in conformity with European Community Council Directive of 1 5 Dec 2004 on the appro ximation of the laws of the Member Stat es relating to electromagnetic compatibilit y , 2004/1 08/EC . It was manuf actured in conformit y with a national standar d that im[...]

SAFETY 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 surr ounding ar ea ma y ext end bey ond the boundar ies of the premises. Methods of Reducing Emissions Mains Supply W elding equipment should be connected to the ma[...]

- MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I BULLDOG® 140 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 BULLDOG® 140 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

INST ALLA TION A-2 A-2 BULLDOG® 140 TECHNICAL SPECIFICA TIONS - Bulldog® 140 K2708-1 Manufacturer Description Speed Displacement Ignition Capacities Robin / Subaru 1 cyl., 3700 RPM 17.51 cu. in. Manual, Fuel: 6.86 gal. (24.9 l) EX 30 4 cycle ± 50 RPM (287 cc) Recoil start; Code air-cooled at no load Manual choke Oil: 1.1 qts.(1.0 l) (1 1518) OHC[...]

INST ALLA TION A-3 A-3 BULLDOG® 140 SAFETY PRECAUTIONS Read this entire installation section before you start installation. 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 m[...]

INST ALLA TION A-4 A-4 BULLDOG® 140 Robin / Subaru 10 HP Carb. Certified EX 30 .31 Gallons/Hour (1.16 Liters/Hour) .53 Gallons/Hour (2.02 Liters/Hour) .70 Gallons/Hour (2.65 Liters/Hour) No Load 3750 RPM ±100 R.P .M. AC CC Weld Output 80 Amps @ 25 V olts Auxiliary Power 4000 W atts (120/240 V olts) Bulldog® 140 T ypical Fuel Consumption SP ARK A[...]

INST ALLA TION A-5 A-5 BULLDOG® 140 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 becom[...]

INST ALLA TION A-6 A-6 BULLDOG® 140 Cable Installation Install the welding cables to your Bulldog® 140 as fol- lows. See Figure A.1 for the location of parts. 1. 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 ou[...]

INST ALLA TION A-7 A-7 BULLDOG® 140 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 . Certai[...]

Certain Electrical devices cannot be powered by the Bulldog® 140. See T able A.2. T ABLE A.2 ELECTRICAL DEVICE USE WITH THE Bulldog® 140. T ype Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker . Capacitive TV sets, radios, microwaves, V oltage sp[...]

T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 BULLDOG® 140 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OPERA TION B-2 B-2 BULLDOG® 140 SAFETY INSTRUCTIONS Read and understand this entire section before oper- ating your Bulldog® 140. 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[...]

OPERA TION B-3 B-3 BULLDOG® 140 LIMIT A TIONS • The Bulldog® 140 is not recommended for any processes besides those that are normally per- formed using stick welding (SMA W) 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[...]

OPERA TION B-4 B-4 BULLDOG® 140 GASOLINE ENGINE CONTROLS Refer to your engine manual for the location of the fol- lowing features: 1. FUEL SHUTOFF V AL VE: Stops the flow of gaso- line from the fuel tank to the carburetor . Should be closed whenever you are finished using the Bulldog® 140. Must be opened before you start the engine. 2. FUEL T ANK[...]

OPERA TION B-5 B-5 BULLDOG® 140 4. Pull the cord rapidly . 5. If the 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. T o open the choke fully requires an engine warm-up period of several sec- onds to several minutes, depending on t[...]

OPERA TION B-6 B-6 BULLDOG® 140 GENERA TOR OPERA TION Be 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 powered by the Bulldog® 140. Refer to T able A.2, ELECTRI- CAL DEVICE USE WITH THE Bulldog® 140 , in th[...]

OPERA TION B-7 B-7 BULLDOG® 140 T ABLE B.1 GENERA TOR POWER APPLICA TIONS Suggested Power Applications Running W atts *Start-up W atts ( C o nt in uo us ) ( Su rg e) *Air Compressor - 1 HP 2,000 4,000 - 8,000 *Air Compressor - 3/4 HP 1,250 3,100 - 5,000 *Airless Sprayer - 1/3 HP 600 1,500 - 2,400 Chain Saw 1,200 Circular Saw 1,200 Coffee Maker 1,0[...]

OPERA TION B-8 B-8 BULLDOG® 140 WELDING OPERA TION GENERAL INFORMA TION ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ The[...]

OPERA TION B-9 B-9 BULLDOG® 140 Stick welding is probably the most 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 wi[...]

OPERA TION B-10 B-10 BULLDOG® 140 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 manua[...]

OPERA TION B-11 B-11 BULLDOG® 140 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 [...]

OPERA TION B-12 B-12 BULLDOG® 140 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: 3/16” (4.8mm), or[...]

OPERA TION B-13 B-13 BULLDOG® 140 Now weld the two plates together . Weld from left to 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. W atch the molten metal to be sure it distributes itself evenly on both edges and in between the plates. Penetr[...]

OPERA TION B-14 B-14 BULLDOG® 140 V ertical-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: 1. Use 1/8” (3.2mm) 90-1 15 amps or 3/[...]

OPERA TION B-15 B-15 BULLDOG® 140 Overhead Welding V arious 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 A WS 601 1 electrode on AC. 2. Put t[...]

OPERA TION B-16 B-16 BULLDOG® 140 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 .) 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 wi[...]

OPERA TION B-17 B-17 BULLDOG® 140 High-Speed Group (A WS E6013) 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 th[...]

NOTES B-18 B-18 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 BULLDOG® 140 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

ACCESSORIES C-2 C-2 BULLDOG® 140 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 ho[...]

T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 BULLDOG® 140 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

MAINTENANCE D-2 D-2 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAINTENANCE D-3 D-3 BULLDOG® 140 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn 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 missi[...]

MAINTENANCE D-4 D-4 BULLDOG® 140 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 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 ma[...]

MAINTENANCE D-5 D-5 BULLDOG® 140 ROBIN / SUBARU P ART # Champion RL 86C (GAP .025” [.65mm]) 279-32612-08 P ART SP ARK PLUG (RESISTOR) AIR FIL TER ELEMENT Refer to T able D.1 for engine maintenance parts. The part numbers are accurate at the time of printing. (V erify the current part number by referring to the engine owner ’s manual. CLEAN OR [...]

MAINTENANCE D-6 D-6 BULLDOG® 140 GENERA TOR/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. BRU SH RE MOV AL A ND R EPLA CEM ENT : See Figure D.6. It’s normal for the br[...]

MAINTENANCE D-7 D-7 BULLDOG® 140 2 3 4 8 1 5 9 6 7 10 11 12 13 FIGURE D.7. - MAJOR COMPONENT LOCA TIONS 1. CRADLE ASSEMBL Y 2. ROTOR, BLOWER, AND BEARING ASSEMBL Y 3. ST A TOR ASSEMBL Y 4. BRUSH, BRUSH HOLDER ASSEMBL Y AND BEARING BRACKET END COVER 5. REAR CONTROL P ANEL 6. REAR P ANEL ASSEMBL Y 7. FUEL T ANK ASSEMBL Y 8. CONTROL P ANEL ASSEMBL Y [...]

NOTES D-8 D-8 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 BULLDOG® 140 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Engine, Excitation, Rotor And Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

THEOR Y OF OPERA TION E-2 E-2 BULLDOG® 140 ENGINE, EXCIT A TION, ROTOR AND ST A TOR 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 mag ne tizes the rotor lamination. The rotor is mechanically coupled to [...]

THEOR Y OF OPERA TION E-3 E-3 BULLDOG® 140 ROTOR FIELD FEEDBACK AND AUXILIAR Y 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 [...]

THEOR Y OF OPERA TION E-4 E-4 BULLDOG® 140 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 [...]

T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 BULLDOG® 140 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

TROUBLESHOOTING AND REP AIR F-2 F-2 BULLDOG® 140 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the m[...]

TROUBLESHOOTING AND REP AIR F-3 F-3 BULLDOG® 140 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o 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 [...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 trouble[...]

NOTES F-12 F-12 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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 thr[...]

200 A LEAD 200A CONNECTION GROUND STUD FIGURE F .1 – LOCA TION OF LEAD 200A FOR ROTOR VOL T AGE TEST ROT OR VOL T AGE TEST (continued) 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 . 2. Start the machine and run it at high idle. Set the output control ([...]

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 thr[...]

+ ~ ~ - + - POSITIVE DC NEGA TIVE DC SINGLE PHASE BRIDGE CIRCUIT CONFIGURA TION FIGURE F .2 – DIODE BRIDGE CIRCUIT CONFIGURA TION FIELD DIODE BRIDGE TEST (continued) 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 t[...]

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 thr[...]

SLIP RINGS 201A(-) 202A(+) FIGURE F .3 – BRUSH HOLDER LEADS 201(-) AND 202B (+) FIGURE F .4 – DIODE BRIDGE LEAD ASSIGNMENTS ROT OR “FLASHING” CIRCUIT TEST (continued) PROCEDURE 1. With the 3/8” nutdriver , remove the 20 sheet metal screws that hold the top cover to the con- trol box. Remove the top cover . 2. Locate and remove lead #201A [...]

ROT OR “FLASHING” CIRCUIT TEST (continued) MOVING P ARTS can injure. Keep away from moving parts. ------------------------------------------------------------------- ENGINE EXHAUST can kill. Use in open, well ventilated areas or vent exhaust to the outside. ------------------------------------------------------------------- 5. Start the engine [...]

NOTES F-20 F-20 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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 thr[...]

SLIP RINGS FIGURE F .5 – LOCA TION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBL Y REMOVED ROT OR RESIST ANCE TEST (continued) PROCEDURE 1. Conduct the test with the gasoline engine OFF . 2. Remove the spark plug wire to prevent acci- dental engine kickback or starting. 3. Isolate the rotor electrically by removing the generator brushes. Refer to Fi[...]

CABLE TIE BRUSHES FIGURE F .6 – BRUSHES RET AINED WITH CABLE TIE ROT OR RESIST ANCE TEST (continued) 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 [...]

NOTES F-24 F-24 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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 thr[...]

MARK FIGURE F .7 – MARK LOCA TION ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) 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. 2. With the black or red marking pencil, place a mark on one of the blow[...]

THRO T TLE L OCKING NUT FIGURE F .8 – LOCKING NUT LOCA TION HIGH SPEED ST OP SCRE W FIGURE F .9 – ST OP SCREW LOCA TION ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) 2. Using the 10mm socket wrench, slightly loosen the throttle locking nut. See Figure F .8. 3. Using the screwdriver , adjust the high speed stop screw until the [...]

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 V olts/Div .....................50V/Div . Horizontal Sweep .....5 ms/D[...]

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 1 15 V AC receptacle. SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep .....5 [...]

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 V olts/Div .......[...]

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 thr[...]

CABLE TIE BRUSHES FIGURE F .10 – BRUSHES RET AINED WITH CABLE TIE BRUSH REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wire. 2. 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. 3. With the 1/4”[...]

BRUSH REMOV AL AND REPLACEMENT (continued) 8. T o reinstall the brush holder assembly , depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder . A cable tie works well; see Figure F .10 . This will hold the brushes up so that you can easily inst[...]

NOTES F-34 F-34 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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 thr[...]

FIGURE F .1 1 – RHEOST A T REMOV AL RHEOST A T REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove the 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 . 3. With the small slot head screw driver , loosen the screw that holds the knob to the rhe[...]

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 thr[...]

201 201A (-) 202 202A (+) Attachment for Attachment for Jumper Capacitor Cable T ie FIGURE F .12 – LOCA TION AND DISCHARGING THE FIELD CAP ACITOR CAP ACITOR AND/OR DIODE BRIDGE REMOV AL AND REPLACEMENT (continued) PROCEDURE - CAP ACITOR REMOV AL AND REPLACEMENT 1. Remove the engine spark plug wire. 2. With the 3/8” nut driver , remove the 4 she[...]

Feild Diode Bridge CAP ACITOR AND/OR DIODE BRIDGE REMOV AL AND REPLACEMENT (continued) PROCEDURE - FIELD DIODE BRIDGE REMOV AL AND REPLACEMENT 1. Remove the engine spark plug wire. 2. With the 3/8” nut driver , remove the 8 sheet metal screws that hold the top cover to the con- trol box. Remove the top cover . 3. With the 3/8” nut driver and wr[...]

NOTES F-40 F-40 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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 thr[...]

GENERA TOR ENGINE FIGURE F .14 – GENERA TOR AND ENGINE LOCA TION ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 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/of f switch on the rear of the engin[...]

BEARING BRACKET END COVER END BRACKET MACHINING ST A TOR LAMINA TION ASSEMBL Y THRU BOL T ROTOR BRUSH ASSEMBL Y FIGURE F .15 – GENERA TOR COMPONENTS ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 6. Remove the brush assembly from the slip ring end bracket. 7. Remove the (4) long HHCS and hardware along with the slip ring end bracket. 8. Car[...]

ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 12. If impact wrench is available, rapidly torque impact bolt 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.[...]

OUTPUT TERMINALS W1 W2 TIE WRAP FIGURE F .16 – OUTPUT LEAD LOCA TION ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) ST A TOR REMOV AL PROCEDURE 1. Remove engine spark plug wire to prevent acci- dental kickback or starting. 2. With the 5/16” nutdriver , remove the 4 sheet metal screws that hold the top cover to the con- trol box. Remove th[...]

THRU- BOL TS THRU- BOL TS NUTS SUPPORT FIGURE F .17 – ST A TOR END BRACKET SUPPORT AND THRU-BOL TS ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 12. Slide a short length of 2 X 4 under the engine to support it when the stator is removed. 13. With the 1/2” socket wrench, remove the 2 nuts that hold the stator end bracket support. See Figu[...]

ROT OR THRU-BOL T FIGURE F .18 – ROT OR WITH ST A TOR REMOVED ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) ROTOR REMOV AL PROCEDURE 1. T o remove the rotor , double check that the spark plug wire is disconnected. Y ou will be turning the rotor during this procedure, and this could accidentally cause engine kickback. 2. With an impact wren[...]

ROTOR ST A TOR FEELER GAUGE FIGURE F .19 – CHECKING ROTOR-ST A TOR AIR GAP ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 6. 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. T ap the end bracket with the mallet as neces- sary to position it. Tighten the b[...]

TROUBLESHOOTING AND REP AIR F-49 F-49 BULLDOG® 140 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. ENGINE OUTPUT No Load RPM Load RPM Maximu[...]

NOTES F-50 F-50 BULLDOG® 140 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 BULLDOG® 140 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (L15064) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

ElEcTrical DiaGramS G-2 BullDOG® 140 WiriNG DiaGram - cOmplETE machiNE - (l15064) 6 5 3 CB1 20 A J6 9 7 + - ROTOR FIELD S LI P RI NG S W1 W2 CB1 20 A 6A 6B GND -F 3B 3A GND-E 3 GN D-C GROUN D S TU D O N CO NT RO L PANE L F RO NT WORK GND-H GN D-C 5 5A 5A NE UT RA L S TU D O N CO NT ROL PANE L BO TT OM GND GN D MO DU LE LOW OIL SW IT CH RUN/ ST OP [...]

ElEcTrical DiaGramS G-3 BullDOG® 140 SchEma Tic - cOmplETE machiNE - (S28101) S28101 BU LL DO G 140 MACHI N E SCHE M AT IC NONE S28100 mp atr z yk APM DRS DO N OT S CA L E TH IS D RA WING DR AW N BY : ENGIN EER : EQ UIPM ENT TY PE: SUBJECT: SC ALE : UF CR M40 76 0-A 1 PAGE _ _ _ OF __ _ 1 EN GI NEE RIN G CO NTR OL L ED M AN UF ACTU RE R: No R EVIS[...]