Lincoln Electric SVM208-A Welding and Cutting Sparks can cause fire or explosion, Iii

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SAFETY

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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.

6.b. Where compressed 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.

6.c. 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.

6.d. 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).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. 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.

6.g. 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 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.

6.h. Also see item 1.c.

6.I. 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.

CYLINDER may explode if damaged.

7.a. 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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “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.

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 the U.S. National Electrical Code and the manufacturer’s recommendations.

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6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

BULLDOG® 140

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Contents Bulldog Safety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousCylinder may explode if damaged Welding and Cutting Sparks can cause fire or explosionIii 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 K2708-1Safety Precautions Location and VentilationStoring Engine Exhaust can killPRE-OPERATION Engine Service StackingTilting OILWelding Cable Connections Electrical Output CONNEC- TionsTable A.1 Recommended Welding Cable Size and Length Auxiliary Power Receptacles Cable InstallationElectrical Connections Plugs and HAND-HELD EquipmentPremises Wiring Circuit BreakersAtion. do not RUN These BulldogTable of Contents Operation Section Operation WELDER/GENERATOR Controls LimitationsOutput Panel Controls Engine Operation Gasoline Engine ControlsBefore Starting the Engine Starting the EngineGenerator Operation Table B.1 Generator Power Applications Welding Operation Control Function / OperationMaterial Thickness Electrode Type Size Setting Welding GuidelinesStick Welding Learning To Stick WeldWhat Happens in the Arc? Correct Welding Position Side viewPractice Use the followingDo the following Butt JointsFillet Joints PenetrationVertical-Up Welding Vertical-Down WeldingHow to Hardface the Sharp Edge Metal to Ground Wear Overhead WeldingWelding Sheet Metal Hardfacing To Reduce WearWelding Cast Iron Cast Iron Plate PreparationLow 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 Engine Adjustments Return to Section TOC To Section TOCSpark Plug Service Table D.1 Engine Maintenance PartsOperational 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 Test Description Rotor Voltage TestMaterials Needed Rotor Voltage Test ProcedureLead 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 Engine Throttle Adjustment Test ROBIN/SUBARU EngineStrobe-tach Method Frequency Counter MethodHigh Speed Stop Screw Scope Settings Normal Open Circuit Voltage Waveform 115VAC Supply High Idle no LoadMachine Loaded Typical Weld Output WaveformMachine 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 Procedure Capacitor Removal and Replacement 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 Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1Bulldog Table of Contents Diagram Section Wiring Diagram Bulldog S28101