Lincoln Electric SVM208-A service manual Bulldog

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SVM208-A

January, 2011

BULLDOG® 140

For use with machine code number: 11518

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 EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON- TAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

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

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Contents Bulldog California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnCylinder may explode if damaged Welding and Cutting Sparks can cause fire or explosionIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Bulldog 140 K2708-1 InstallationLocation and Ventilation Safety PrecautionsStoring Engine Exhaust can killStacking PRE-OPERATION Engine ServiceTilting OILWelding Cable Connections Electrical Output CONNEC- TionsTable A.1 Recommended Welding Cable Size and Length Cable Installation Auxiliary Power ReceptaclesElectrical Connections Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringBulldog Ation. do not RUN TheseTable of Contents Operation Section Operation WELDER/GENERATOR Controls LimitationsOutput Panel Controls Gasoline Engine Controls Engine OperationStarting the Engine Before Starting the EngineGenerator Operation Table B.1 Generator Power Applications Control Function / Operation Welding OperationWelding Guidelines Material Thickness Electrode Type Size SettingStick Welding Learning To Stick WeldWhat Happens in the Arc? Side view Correct Welding PositionUse the following PracticeDo the following Butt JointsPenetration Fillet JointsVertical-Down Welding Vertical-Up WeldingOverhead Welding How to Hardface the Sharp Edge Metal to Ground WearWelding Sheet Metal Hardfacing To Reduce WearCast Iron Plate Preparation Welding Cast IronLow Hydrogen Group AWS E7018 High-Speed Group AWS E6013Out-of-Position Group AWS E6011 Bulldog Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Engine Maintenance Routine and Periodic MaintenanceLocation Return to Section TOC To Section TOC Engine AdjustmentsSpark Plug Service Table D.1 Engine Maintenance PartsOperational Clearance Screws Brushes GENERATOR/WELDER MaintenanceFigure D.7. Major Component Locations Bulldog 1TABLE of CONTENTS-THEORY of Operation Section E-1 ENGINE, EXCITATION, Rotor Stator Theory of OperationFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent Protection1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairPC Board Troubleshooting Procedures Output Problems Perform the Rotor Voltage Test Electric Authorized Field Ser vice FacilityProblems Symptoms Troubleshooting and Repair Perform Field Diode Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Bulldog Test Description Rotor Voltage TestMaterials Needed Rotor Voltage Test ProcedureLead 200A Connection Ground Stud Field Diode Bridge Test + ~ Field Diode Bridge TestRotor Flashing Circuit Test Figure F.3 Brush Holder Leads 201- and 202B + Rotor Flashing Circuit TestMoving Parts can injure Bulldog Rotor Resistance Test Rotor Resistance Test Figure F.6 Brushes Retained with Cable TIE Cable TIE BrushesBulldog Engine Throttle Adjustment Test ROBIN/SUBARU Engine ROBIN/SUBARU Engine Engine Throttle Adjustment TestStrobe-tach Method Frequency Counter MethodHigh Speed Stop Screw Scope Settings High Idle no Load Normal Open Circuit Voltage Waveform 115VAC SupplyMachine Loaded Typical Weld Output WaveformMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement Cable TIE Brushes Brush Removal and ReplacementReturn to Section Return to Section TOC Bulldog Rheostat Removal and Replacement Figure F.11 Rheostat Removal Rheostat Removal and ReplacementCapacitor AND/OR Diode Bridge Removal and Replacement Procedure Capacitor Removal and Replacement Removal and ReplacementCapacitor AND/OR Diode Bridge Figure F.13 Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementBulldog Instructions STATOR/ROTOR Removal and ReplacementGeneratorengine STATOR/ROTOR Removal and ReplacementFigure F.15 Generator Components Troubleshooting and Repair Figure F.16 Output Lead Location TIE Wrap Terminals Stator Removal ProcedureNuts Thru Bolts SupportReassembly Procedure Rotor Removal ProcedureFigure F.19 Checking ROTOR-STATOR AIR GAP Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1Bulldog Table of Contents Diagram Section Wiring Diagram Bulldog S28101