Lincoln Electric SVM208-A service manual Electrical Connections, Plugs and HAND-HELD Equipment

Page 14

A-6

INSTALLATION

A-6

 

 

 

 

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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 output terminals. You can connect either cable to either terminal, since the Bulldog® 140 provides AC weld current.

4.Tighten the flanged nuts securely.

5.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.

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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 combustible material.

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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 Figure A.1. The 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.

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AUXILIARY POWER RECEPTACLES

The control panel of the Bulldog® 140 features two auxiliary power receptacles:

A 20 amp, 120 volt duplex (double outlet) receptacle

A 20 amp 240 volt simplex (single outlet) receptacle. See Figure A.1.

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

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Contents Bulldog Safety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousIii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Bulldog 140 K2708-1Storing Safety PrecautionsLocation and Ventilation Engine Exhaust can killTilting PRE-OPERATION Engine ServiceStacking OILTable A.1 Recommended Welding Cable Size and Length Electrical Output CONNEC- TionsWelding Cable Connections Electrical Connections Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD EquipmentPremises Wiring Circuit BreakersAtion. do not RUN These BulldogTable of Contents Operation Section Operation Output Panel Controls LimitationsWELDER/GENERATOR Controls Engine Operation Gasoline Engine ControlsBefore Starting the Engine Starting the EngineGenerator Operation Table B.1 Generator Power Applications Welding Operation Control Function / OperationStick Welding Material Thickness Electrode Type Size SettingWelding Guidelines Learning To Stick WeldWhat Happens in the Arc? Correct Welding Position Side viewDo the following PracticeUse the following Butt JointsFillet Joints PenetrationVertical-Up Welding Vertical-Down WeldingWelding Sheet Metal How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Hardfacing To Reduce WearWelding Cast Iron Cast Iron Plate PreparationOut-of-Position Group AWS E6011 High-Speed Group AWS E6013Low Hydrogen Group AWS E7018 Bulldog Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Maintenance Location Routine and Periodic MaintenanceEngine Maintenance Engine Adjustments Return to Section TOC To Section TOCOperational Clearance Table D.1 Engine Maintenance PartsSpark Plug Service GENERATOR/WELDER Maintenance Screws BrushesFigure D.7. Major Component Locations Bulldog 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation ENGINE, EXCITATION, Rotor StatorRotor Field Feedback Auxiliary Power Figure E.3 Rotor Field Feedback and Auxiliary PowerAuxiliary Power Overcurrent Protection Weld Winding and Reactor1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Output Problems Electric Authorized Field Ser vice Facility Perform the Rotor Voltage TestProblems Symptoms Troubleshooting and Repair Perform Field Diode Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Bulldog Materials Needed Rotor Voltage TestTest Description Lead 200A Connection Ground Stud ProcedureRotor Voltage Test Field Diode Bridge Test Field Diode Bridge Test + ~Rotor Flashing Circuit Test Rotor Flashing Circuit Test Figure F.3 Brush Holder Leads 201- and 202B +Moving Parts can injure Bulldog Rotor Resistance Test Rotor Resistance Test Cable TIE Brushes Figure F.6 Brushes Retained with Cable TIEBulldog Engine Throttle Adjustment Test ROBIN/SUBARU Engine Strobe-tach Method Engine Throttle Adjustment TestROBIN/SUBARU Engine Frequency Counter MethodHigh Speed Stop Screw Scope Settings Normal Open Circuit Voltage Waveform 115VAC Supply High Idle no LoadMachine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Brush Removal and Replacement Brush Removal and Replacement Cable TIE BrushesReturn to Section Return to Section TOC Bulldog Rheostat Removal and Replacement Rheostat Removal and Replacement Figure F.11 Rheostat RemovalCapacitor AND/OR Diode Bridge Removal and Replacement Capacitor AND/OR Diode Bridge Removal and ReplacementProcedure Capacitor Removal and Replacement Procedure Field Diode Bridge Removal and Replacement Figure F.13 Field Diode Bridge LocationBulldog STATOR/ROTOR Removal and Replacement InstructionsSTATOR/ROTOR Removal and Replacement GeneratorengineFigure F.15 Generator Components Troubleshooting and Repair Stator Removal Procedure Figure F.16 Output Lead Location TIE Wrap TerminalsThru Bolts Support NutsRotor Removal Procedure Reassembly ProcedureFigure F.19 Checking ROTOR-STATOR AIR GAP Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1Bulldog Table of Contents Diagram Section Wiring Diagram Bulldog S28101