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Lincoln Electric BULLDOG SVM208-A Service Manual

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RETURN TO MAIN MENU
SVM208-A
January, 2011
®
BULLDOG
140
11518
For use with machine code number:
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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Summary of Contents for Lincoln Electric BULLDOG SVM208-A

  • Page 1 RETURN TO MAIN MENU SVM208-A January, 2011 ® BULLDOG 11518 For use with machine code number: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety increased by proper installation .

  • Page 2: California Proposition 65 Warnings

    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. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b.
  • Page 4 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 SAFETY Electromagnetic Compatibility (EMC) Conformance Introduction Installation and Use Assessment of Area BULLDOG® 140...
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) Methods of Reducing Emissions Mains Supply Maintenance of the Welding Equipment Welding Cables Equipotential Bonding Earthing of the Workpiece Screening and Shielding BULLDOG® 140...
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 TECHNICAL SPECIFICATIONS - Bulldog® 140 K2708-1 Manufacturer Description Robin / Subaru 1 cyl., EX 30 4 cycle Code air-cooled (11518) OHC gasoline 10 HP @ 3600 RPM Aluminum Block with Cast Iron Sleeve Duty Cycle 30% Duty Cycle 60% Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges 70 - 140 Amps AC...

  • Page 11: Installation

    SAFETY PRECAUTIONS Read this entire installation section before you start installation. 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;...

  • Page 12: Pre-Operation Engine Service

    STACKING Bulldog® 140 machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound. The gasoline engine is designed to run in a level posi- tion for best performance.

  • Page 13: Electrical Output Connections

    Bulldog® 140 OUTPUT CONNECTIONS 1. CURRENT CONTROL DIAL 2. WELD OUTPUT TERMINALS (2) 3. GROUND STUD 4. CIRCUIT BREAKER 20 Amp ELECTRICAL OUTPUT CONNEC- TIONS See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit break- ers, 240 and 120 volt receptacles.

  • Page 14: Electrical Connections

    • Do not cross the welding cables at the output ter- minal connection. Keep the cables isolated and separate from one another. ------------------------------------------------------------------------ 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...

  • Page 15: Premise Wiring

    INSTALLATION PREMISES WIRING The Bulldog® 140 is not recommended for premises wiring. 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.
  • Page 16 Capacitive/Inductive Computers, high resolution TV sets, complicated electrical equipment. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the Bulldog® 140. INSTALLATION CAUTION TABLE A.2 BULLDOG®...
  • Page 17 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Instructions .

  • Page 18: General Description

    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;...

  • Page 19: Controls And Settings

    LIMITATIONS • The Bulldog® 140 is not recommended for any processes besides those that are normally per- formed using stick welding (SMAW) procedures. • The Bulldog® 140 is not recommended for pipe thawing. • During welding, generator power is limited to 100 watts, and output voltages can drop from 120 to 80 volts and 240 to 160 volts.

  • Page 20: Engine Operation

    GASOLINE ENGINE CONTROLS Refer to your engine manual for the location of the fol- lowing features: 1. FUEL SHUTOFF VALVE: Stops the flow of gaso- line from the fuel tank to the carburetor. Should be closed whenever you are finished using the Bulldog®...
  • Page 21 BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL: 1. Place the machine on a level sur- face. 2. Open the oil fill plug. 3. Fill (if necessary) until oil flows out the top of the fill plug hole. 4.

  • Page 22: Generator Operation

    STOPPING THE ENGINE 1. Remove all welding and generator power loads and let the engine cool by running it for several minutes. 2. Stop the engine by placing the “ON/OFF” switch in the “OFF”(O) position. 3. Close the fuel shutoff valve. WARNING Close the fuel valve when the machine is trans- ported to prevent fuel leakage from the carburetor.
  • Page 23 Suggested Power Applications *Air Compressor - 1 HP *Air Compressor - 3/4 HP *Airless Sprayer - 1/3 HP Chain Saw Circular Saw Coffee Maker *Deep Freezer *Electric Motor - 1 HP Electric Range (1 element) Electric Skillet *Furnace Fan - 1/3 HP Portable Grinder (4 1/2”) Portable Grinder (7”) Halogen Work Light...

  • Page 24: Welding Operation

    WELDING OPERATION WARNING GENERAL INFORMATION ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ The Bulldog®...
  • Page 25 The serviceability of a product or structure utiliz- ing this type of information is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information. These variables include,...
  • Page 26 B-10 No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced welder understand welding and develop his skill. For more detailed information, order a copy of the book “New Lessons in Arc Welding.” (See Book Division section at rear of manual).
  • Page 27 B-11 The function of the covered electrode is much more than simply to carry current to the arc. The electrode is composed of a core metal wire around which has been extruded and baked a chemical covering. The core wire melts into the arc and tiny droplets of molten metal shoot across the arc into the molten pool.
  • Page 28 B-12 PRACTICE The best way of getting practice in the four skills that enable you to maintain: 1. Correct Welding Position. 2. Correct Way to Strike An Arc. 3. Correct Arc Length. 4. Correct Welding Speed. is to spend a little more time on the following exercise. Use the following: Mild Steel Plate: 3/16”...
  • Page 29 B-13 Now weld the two plates together. Weld from left to 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. 90° end view Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates.
  • Page 30 B-14 Vertical-Up Welding The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there. If too much molten metal is deposited, gravity will pull it downwards and make it “drip”. Therefore, a certain technique has to be followed: Long arc Short arc...
  • Page 31 B-15 Overhead Welding Various techniques are used for overhead welding. However, in the interest of simplicity for the inexperi- enced welder, the following technique will probably take care of his needs for overhead welding: 1. Use 1/8” (3.2mm) 90-105 A or 3/32” (2.5mm) 70 A AWS 6011 electrode on AC.
  • Page 32 B-16 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 not let the arc blow over the edge, as that will dull the edge. (See drawing below.) Strike Arc Work Table Here Brick Plow Share...
  • Page 33 B-17 In some instances a back-up strip may be used and plates may be gapped 1/8” (3.2mm) or more, as shown in figure (b). Scrap steel back-up strip Three ways to prepare plates where complete penetration is necessary. On sections where only a sealed joint is required and strength is not important, the joint may be welded after slightly veeing out the seam as shown in figure (d) below.
  • Page 34 NOTES B-18 B-18 BULLDOG® 140...
  • Page 35 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Options/Accessories .
  • Page 36 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 37 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Instructions .
  • Page 38 MAINTENANCE BULLDOG® 140...

  • Page 39: Safety Precautions

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to per- form maintenance and replace them when the maintenance requiring their removal is com- plete.

  • Page 40: Engine Adjustments

    FUEL: At the end of each day’s use, refill the fuel tank to minimize moisture condensa- tion and dirt contamination in the fuel line. ENGINE ADJUSTMENTS WARNING OVERSPEED IS HAZARDOUS - The maximum allowable high idle speed for this machine is 3750 RPM, no load.
  • Page 41 SPARK PLUG SERVICE To service spark plug, remove the 8 screws securing the side panel. See Figure D.4. FIGURE D.4 - SIDE PANEL SCREW LOCATIONS CLEAN OR REPLACE SPARK PLUG: Clean or replace the spark plug after every 100 hours of opera- tion or every season, whichever comes first.
  • Page 42 GENERATOR/WELDER MAINTENANCE STORAGE: Store the Bulldog® 140 in clean, dry, protected areas. CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: See Figure D.6.
  • Page 43 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.
  • Page 44 NOTES BULLDOG® 140...
  • Page 45 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Engine, Excitation, Rotor And Stator .
  • Page 46 THEORY OF OPERATION FIGURE E.2 - ENGINE, EXCITATION, ROTOR AND STATOR ENGINE MECHANICAL ROTATION MAGNETO ENGINE, EXCITATION, ROTOR AND STATOR A small voltage developed by the engine magneto is fed through a diode to the rotating field coil in the rotor via a brush and slip ring configuration.

  • Page 47: Auxiliary Power

    THEORY OF OPERATION FIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER ENGINE MECHANICAL ROTATION MAGNETO ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed to the full wave bridge. The DC output of the bridge is fil- tered by the field capacitor and controlled by the output rheostat.

  • Page 48: Theory Of Operation

    THEORY OF OPERATION FIGURE E.4 - WELD WINDING, REACTOR AND AUXILIARY POWER OVERCURRENT PROTECTION ENGINE MECHANICAL ROTATION MAGNETO WELD WINDING AND REACTOR The AC voltage developed in the stator weld winding is delivered, through the reactor, to the machine output terminals.
  • Page 49 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 50: Troubleshooting And Repair

    TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 51: Pc Board Troubleshooting Procedures

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.
  • Page 52 Major physical or electrical damage is evident. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 53 - engine runs normally. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 54 - engine runs normally. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 55 - engine runs normally. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 56 Low weld output and low auxiliary output. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 57 Engine will not start. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 58 Engine sputters but will not start. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 59 Auxiliary power is func- tioning normally. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 60 NOTES F-12 F-12 BULLDOG® 140...

  • Page 61: Rotor Voltage Test

    TROUBLESHOOTING AND REPAIR F-13 Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 62 TROUBLESHOOTING AND REPAIR F-14 ROTOR VOLTAGE TEST (continued) FIGURE F.1 – LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST LEAD 200A CONNECTION PROCEDURE 1. With the 3/8” nut driver, remove the 4 sheet metal screws that hold the top cover to the con- trol box.

  • Page 63: Field Diode Bridge Test

    F-15 FIELD DIODE BRIDGE TEST Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 64 TROUBLESHOOTING AND REPAIR F-16 F-16 FIELD DIODE BRIDGE TEST (continued) FIGURE F.2 – DIODE BRIDGE CIRCUIT CONFIGURATION POSITIVE DC SINGLE PHASE BRIDGE CIRCUIT CONFIGURATION NEGATIVE DC PROCEDURE The diode bridge is configured as pictured above. The individual diodes can be tested using a diode tester or an ohm meter.

  • Page 65: Rotor "Flashing" Circuit Test

    F-17 ROTOR “FLASHING” CIRCUIT TEST Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 66 TROUBLESHOOTING AND REPAIR F-18 ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F.3 – BRUSH HOLDER LEADS 201(-) AND 202B (+) SLIP RINGS PROCEDURE 1. With the 3/8” nutdriver, remove the 20 sheet metal screws that hold the top cover to the con- trol box.
  • Page 67 TROUBLESHOOTING AND REPAIR F-19 ROTOR “FLASHING” CIRCUIT TEST (continued) WARNING MOVING PARTS can injure. Keep away from moving parts. ------------------------------------------------------------------- ENGINE EXHAUST can kill. Use in open, well ventilated areas or vent exhaust to the outside. ------------------------------------------------------------------- 5. Start the engine and run it at High Idle (3700 - 3800 RPM).
  • Page 68 NOTES F-20 F-20 BULLDOG® 140...

  • Page 69: Rotor Resistance Test

    F-21 ROTOR RESISTANCE TEST Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 70 TROUBLESHOOTING AND REPAIR F-22 ROTOR RESISTANCE TEST (continued) FIGURE F.5 – LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED SLIP RINGS PROCEDURE 1. Conduct the test with the gasoline engine OFF. 2. Remove the spark plug wire to prevent acci- dental engine kickback or starting.
  • Page 71 TROUBLESHOOTING AND REPAIR F-23 ROTOR RESISTANCE TEST (continued) FIGURE F.6 – BRUSHES RETAINED WITH CABLE TIE CABLE BRUSHES 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fair- ly stiff retainer through the slots at the top and bottom of the holder.
  • Page 72 NOTES F-24 F-24 BULLDOG® 140...

  • Page 73: Engine Throttle Adjustment Test Robin/Subaru Engine

    F-25 ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 74 TROUBLESHOOTING AND REPAIR F-26 ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) MARK PROCEDURE This test can be conducted by any of three meth- ods. Strobe-tach Method: 1. Stop the engine and remove the spark plug wire to prevent accidental kickback or starting. 2.
  • Page 75 TROUBLESHOOTING AND REPAIR F-27 ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) FIGURE F.8 – LOCKING NUT LOCATION 2. Using the 10mm socket wrench, slightly loosen the throttle locking nut. See Figure F.8. 3. Using the screwdriver, adjust the high speed stop screw until the waveform period is 16.2 milliseconds.
  • Page 76 TROUBLESHOOTING AND REPAIR F-28 NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD This is the typical AC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 77: Normal Open Circuit Voltage Waveform (115Vac Supply

    TROUBLESHOOTING AND REPAIR F-29 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) 1 Period = 16.2 ms @ 3700 rpm HIGH IDLE – NO LOAD 20 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 78: Typical Weld Output Waveform

    TROUBLESHOOTING AND REPAIR F-30 TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED TO 125 AMPS AT 23 VAC MACHINE LOADED 20 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 20 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 79: Brush Removal And Replacement

    F-31 BRUSH REMOVAL AND REPLACEMENT Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 80 TROUBLESHOOTING AND REPAIR F-32 BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.10 – BRUSHES RETAINED WITH CABLE TIE CABLE BRUSHES PROCEDURE 1. Remove the spark plug wire. 2. Open the brush holder assembly cover. Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fingernail.
  • Page 81 TROUBLESHOOTING AND REPAIR F-33 BRUSH REMOVAL AND REPLACEMENT (continued) 8. To reinstall the brush holder assembly, depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder. A cable tie works well; see Figure F.10.
  • Page 82 NOTES F-34 F-34 BULLDOG® 140...

  • Page 83: Rheostat Removal And Replacement

    F-35 RHEOSTAT REMOVAL AND REPLACEMENT Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 84 TROUBLESHOOTING AND REPAIR F-36 RHEOSTAT REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the spark plug wire. 2. With the 3/8” nut driver, remove the 4 sheet metal screws that hold the top cover to the con- trol box. Remove the top cover. 3.

  • Page 85: Capacitor And/Or Diode Bridge Removal And Replacement

    F-37 CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 86 TROUBLESHOOTING AND REPAIR F-38 CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.12 – LOCATION AND DISCHARGING THE FIELD CAPACITOR Attachment for 202A Cable Tie Capacitor PROCEDURE - CAPACITOR REMOVAL AND REPLACEMENT 1. Remove the engine spark plug wire. 2.
  • Page 87 TROUBLESHOOTING AND REPAIR F-39 CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.13 – FIELD DIODE BRIDGE LOCATION (Black) 201B (Black) – PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT 1. Remove the engine spark plug wire. 2. With the 3/8” nut driver, remove the 8 sheet metal screws that hold the top cover to the con- trol box.
  • Page 88 NOTES F-40 F-40 BULLDOG® 140...

  • Page 89: Stator/Rotor Removal And Replacement

    F-41 STATOR/ROTOR REMOVAL AND REPLACEMENT Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 90: Generator Engine

    TROUBLESHOOTING AND REPAIR F-42 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – GENERATOR AND ENGINE LOCATION GENERATOR PROCEDURE 1. Remove control panel cove by removing the 20 screws with a 3/8” nutdriver. 2. Remove the right case side by removing the 5 screws using a 3/8”...
  • Page 91 TROUBLESHOOTING AND REPAIR F-43 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – GENERATOR COMPONENTS BRUSH ASSEMBLY BEARING BRACKET END COVER 6. Remove the brush assembly from the slip ring end bracket. 7. Remove the (4) long HHCS and hardware along with the slip ring end bracket. 8.
  • Page 92 TROUBLESHOOTING AND REPAIR F-44 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) 12. If impact wrench is available, rapidly torque impact bolt until rotor “pops” off of tapered engine crank. If impact wrench is unavailable, restrain rotor and tighten bolt with socket wrench until rotor “pops”...
  • Page 93 TROUBLESHOOTING AND REPAIR F-45 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – OUTPUT LEAD LOCATION TIE WRAP STATOR REMOVAL PROCEDURE 1. Remove engine spark plug wire to prevent acci- dental kickback or starting. 2. With the 5/16” nutdriver, remove the 4 sheet metal screws that hold the top cover to the con- trol box.
  • Page 94 TROUBLESHOOTING AND REPAIR F-46 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.17 – STATOR END BRACKET SUPPORT AND THRU-BOLTS THRU- BOLTS SUPPORT 12. Slide a short length of 2 X 4 under the engine to support it when the stator is removed. 13.
  • Page 95 TROUBLESHOOTING AND REPAIR F-47 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – ROTOR WITH STATOR REMOVED ROTOR THRU-BOLT ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the spark plug wire is disconnected. You will be turning the rotor during this procedure, and this could accidentally cause engine kickback.
  • Page 96 TROUBLESHOOTING AND REPAIR F-48 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.19 – CHECKING ROTOR-STATOR AIR GAP ROTOR 6. Install the bottom two end bracket thru-bolts. NOTE: The flat washer goes on the top right hand thru-bolt for the green ground wire. 7.
  • Page 97 TROUBLESHOOTING AND REPAIR F-49 Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components. Maximum Speed Minimum Speed WELDER/GENERATOR OUTPUT...
  • Page 98 NOTES F-50 F-50 BULLDOG® 140...
  • Page 99 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (L15064) .
  • Page 100 WiriNG DiaGram - cOmplETE machiNE - (l15064) 201B GND-H NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ElEcTrical DiaGramS WIRING DIAGRAM - BULLDOG 140 ROTOR...
  • Page 101 SchEmaTic - cOmplETE machiNE - (S28101) S28101 WELD WINDING EXCITER WINDING PROPRIETARY & CONFIDENTIAL: MANUFACTURING TOLERANCE PER E2056 UNLESS OTHERWISE SPECIFIED TOLERANCE: ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm) ON ALL ANGLES IS ±...

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Bulldog 140

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