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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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
nd, most
importantly, think before you act
and be careful.
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• 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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BULLDOG ™140
For Machines with Code Number 11518
THIS
Various engine configurations are available and machine appearance will vary
accordingly.
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
IM10005
Copyright © Lincoln Global Inc.
June, 2009
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Table of Contents
Troubleshooting
Related Manuals for Lincoln BULLDOG 140
Summary of Contents for Lincoln BULLDOG 140
- Page 1 BULLDOG ™140 June, 2009 For Machines with 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 thought- ful operation on your part.
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Page 2: California Proposition 65 Warnings
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Safety i-iv Installation ..........................Section A Technical Specifications ......................A-1 Safety Precautions........................A-2 Location and Ventilation ......................A-2 Stacking, tilting and Lifting ......................A-3 Pre-operation Engine Service .....................A-3 Oil, Fuel and Spark Arrester......................A-3 Electrical Output Connections and Welding Cable Size, Lengths..........A-4 Machine Grounding and Auxiliary Power Receptacles...............A-5 Premises Wiring and Circuit Breakers ..................A-6 Electrical Devises used with the BULLDOG™... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - BULLDOG™ 140 K2708-1 INPUT - GASOLINE ENGINE 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;... -
Page 9: Safety Precautions
INSTALLATION SAFETY PRECAUTIONS LOCATION AND VENTILATION Read this entire installation section before you Whenever you use the BULLDOG™ 140, be sure that start installation. clean cooling air can flow through the machine’s gasoline engine and the generator. Avoid dusty, dirty areas. -
Page 10: Pre-Operation Engine Service
INSTALLATION STACKING The BULLDOG™ 140 is shipped with the engine BULLDOG™ 140 machines CANNOT be stacked. filled with SAE 10W30 oil. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This is an TILTING added precaution. Do not screw in dipstick when checking oil level. -
Page 11: Electrical Output Connections
INSTALLATION BULLDOG™ 140 OUTPUT CONNECTIONS FIGURE A.1 1. CURRENT CONTROL DIAL 5. RECEPTACLE - 240 VOLT, 50 AMP 2. WELD OUTPUT TERMINALS (2) 6. DUPLEX RECEPTACLE (2)- 120 VOLT, 20 3. GROUND STUD 4. CIRCUIT BREAKER 20 Amp 7. HOUR METER TABLE A.1 ELECTRICAL OUTPUT RECOMMENDED WELDING CABLE... -
Page 12: Electrical Connections
----------------------------------------------------------- ----------------------------------------------------------- Lincoln Electric offers a welding accessory kit with AUXILIARY POWER RECEPTACLES the properly specified welding cables. See the ACCESSORIES section of this manual for more infor- The control panel of the BULLDOG™ 140 features mation. - Page 13 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. Certain electrical devices cannot be powered by the BULLDOG™...
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Page 14: Electrical Devises Used With The Bulldog™ 140
DO NOT USE THESE DEVICES WITH A BULLDOG™ 140. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect- ed to the BULLDOG™ 140. BULLDOG™ 140... -
Page 15: Operation
They include important safety precautions; detailed engine starting, operating, and mainte- The Lincoln warranty covers the BULLDOG™ 140 (exclud- nance instructions; and parts lists. ing the engine) for 3 years from the date of purchase. The engine is covered by the engine manufacturer’s warranty... -
Page 16: Limitations
1. CURRENT CONTROL DI L: Adjusts continuous current output. The amperages on the dial corre- spond to the approximate amperages needed for specific Lincoln welding electrodes. 2. 20 MP CIRCUIT BRE KER: Provide separate over- load current protection for the 120 Volt and 240 Volt Receptacles 3. -
Page 17: Engine Operation
OPERATION GASOLINE ENGINE CONTROLS 6. CHOKE: Provides a richer air/fuel mix- ture for cold engine starting condi- Refer to your engine manual for the location of the tions. See the topic ENGINE OPERA- following features: TION, below, for details on setting the choke. - Page 18 OPERATION 4. Pull the cord rapidly. BEFORE STARTING THE ENGINE 5. If the engine does not start, open the choke CHECK AND FILL THE ENGINE OIL LEVEL: slightly and pull the starter cord rapidly again. 1. Place the machine on a level When the engine starts, gradually open the choke surface.
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Page 19: Generator Operation
OPERATION GENERATOR OPERATION STOPPING THE ENGINE 1. Remove all welding and generator power loads CAUTION and let the engine cool by running it for several minutes. 2. Stop the engine by placing the “ON/OFF” switch Be sure that any electrical equipment plugged into in the “OFF”(O) position. - Page 20 *Sump Pump 1,500 - 2,400 Toaster 1,100 Weed Trimmer Lincoln Wire Feeder/Welder 4,000 NOTES: Wattages listed are approximate. Check your equipment for actual wattage. Equipment with unusually high *START-UP WATTS are listed. For start-up of other tabled equipment that uses a motor, allow up to 2 times the running watts shown above.
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Page 21: Welding Operation
The numbers on the dial correspond to the average amps needed to weld using specific Lincoln welding CONTROL FUNCTION / OPERATION rods. Table B.2, WELDING APPLICATIONS, gives you the recommended dial settings based on the “Current Control Dial”... -
Page 22: Welding Guidelines
CABLE, a heavy wire which contains the WORK Ask for the Lincoln WELD DIRECTORY (Publication CLAMP. Quality Lincoln cables use many fine copper C2.10) for a complete listing of all Lincoln stick elec- wires with a very flexible insulating covering for the trodes available. -
Page 23: What Happens In The Arc
OPERATION No one can learn to weld simply by reading about it. The electric arc is made between the work and the tip Skill comes only with practice. The following pages end of a small metal wire, the electrode, which is will help the inexperienced welder understand welding clamped in a holder that is held by the welder. -
Page 24: The Correct Welding Speed
B-10 B-10 OPERATION The function of the covered electrode is much more 2. The Correct Way to Strike An Arc than simply to carry current to the arc. The electrode is composed of a core metal wire around which has Be sure the work clamp makes good electrical contact been extruded and baked a chemical covering. -
Page 25: Types Of Welds
B-11 B-11 OPERATION These higher carbon steels can be welded successful- PRACTICE ly in most cases; however, care must be taken to fol- The best way of getting practice in the four skills that low proper procedures, including preheating the metal enable you to maintain: to be welded and, in some cases, carefully controlling the temperature during and after the welding process. - Page 26 B-12 B-12 OPERATION Now weld the two plates together. Weld from left to Fillet Joints 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. When welding fillet joints, it is very important to hold the electrode at a 45°...
- Page 27 B-13 B-13 OPERATION 8. When the arc is brought back to the now solidified Vertical-Up Welding puddle, IT MUST BE SHORT, otherwise no metal will be deposited, the puddle will melt again, and it will “drip”. The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there.
- Page 28 B-14 B-14 OPERATION 4. Move rapidly enough to stay ahead of the molten Overhead Welding slag. A whipping technique may be used to further minimize burn through. Various techniques are used for overhead welding. 5. If you have a choice, use lap joints rather than fil- However, in the interest of simplicity for the inexperi- lets or butts;...
- Page 29 B-15 B-15 OPERATION 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 When breaking not let the arc blow over the edge, as that will dull the weld stays on the edge.
- Page 30 B-16 B-16 OPERATION In some instances a back-up strip may be used and High-Speed Group (AWS E6013) plates may be gapped 1/8” (3.2mm) or more, as This group includes electrodes which have a moder- shown in figure (b). ately forceful arc and deposit rates between those of the out-of-position and high-deposit electrodes.
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Page 31: Accessories
ACCESSORIES 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. -
Page 32: Maintenance
• If guards are missing from the machine, get FIGURE D.1 - OIL DRAIN AND REFILL replacements from a Lincoln Distributor. See LOCATION the EXPLODED VIEW AND PARTS LIST at the back of this manual. - Page 33 ------------------------------------------------------------------------ Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop. 1. FINGER GUARD AREA CAUTION CLEAN COOLING SYSTEM: See Figure D.3.
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Page 34: Engine Maintenance Parts
MAINTENANCE SPARK PLUG SERVICE Replace or clean engine maintenance parts per the interval outlined in the engine owner’s manual. To service spark plug, remove the 8 screws securing the side panel. See Figure D.4. OPERATIONAL CLEARANCE FIGURE D.4 Approximately 12-18” of clearance should be around this unit during operation for air flow. - Page 35 Do this at least sure that the connections are always tight. once a week in particularly dirty areas. NOTE: Lincoln offers a rotor removal kit for any ser- BRUSH REMOVAL AND REPLACEMENT: See vice which requires removal of the rotor from the Figure D.6.
- Page 36 MAINTENANCE FIGURE D.7. - MAJOR COMPONENT LOCATIONS 1. CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY 4. BRUSH, BRUSH HOLDER ASSEMBLY AND BEARING BRACKET END COVER 5. REAR CONTROL PANEL 6. REAR PANEL ASSEMBLY 7. FUEL TANK ASSEMBLY 8.
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Page 37: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 38: Troubleshooting
5. Faulty reactor (L1). CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. BULLDOG™ 140... - Page 39 Authorized Field Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. BULLDOG™ 140...
- Page 40 Engine is seized and recoil start will not move. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. BULLDOG™ 140...
- Page 41 DIAGRAMS Enhanced Diagram BULLDOG™ 140...
- Page 42 DIMENSION PRINT BULLDOG™ 140...
- Page 43 NOTES BULLDOG™ 140...
- Page 44 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 45 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 46 • 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...