Lincoln Electric SVM208-A service manual Operation

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OPERATION

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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 gloves.

FUMES AND GASES can be dangerous.

Keep your head out of fumes.

Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

Keep flammable material away.

Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

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.

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.

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.

RECOMMENDED 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 (SMAW) welding. For more details on using the machine as a welder, see WELD- ING OPERATION 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 60% duty cycle.

The current is continuously 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

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Contents Bulldog Safety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousWelding and Cutting Sparks can cause fire or explosion Cylinder may explode if damagedIii 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 OILElectrical Output CONNEC- Tions Welding Cable ConnectionsTable A.1 Recommended Welding Cable Size and Length Electrical Connections Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD EquipmentPremises Wiring Circuit BreakersAtion. do not RUN These BulldogTable of Contents Operation Section Operation Limitations WELDER/GENERATOR ControlsOutput Panel 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 PreparationHigh-Speed Group AWS E6013 Low Hydrogen Group AWS E7018Out-of-Position Group AWS E6011 Bulldog Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic Maintenance Engine MaintenanceLocation Engine Adjustments Return to Section TOC To Section TOCTable D.1 Engine Maintenance Parts Spark Plug ServiceOperational Clearance 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 Rotor Voltage Test Test DescriptionMaterials Needed Procedure Rotor Voltage TestLead 200A Connection Ground Stud 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 LoadTypical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC 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 Removal and Replacement Procedure Capacitor Removal and ReplacementCapacitor AND/OR Diode Bridge 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