Lincoln BULLDOG 140 Operator'S Manual Download

Page: 38 / 46

E-2

TROUBLESHOOTING

E-2

BULLDOG™ 140

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

No generator power or welding output.

Generator power is available but unit

will not weld.

1. Disconnect anything plugged into

auxiliary receptacles and weld loads.

2. Open lead in flashing or field circuit.

3. Open flashing diode (D1)

4. Faulty brushes.

5. Faulty rheostat (R1).

6. Faulty field rectifier (D1).

7. Faulty capacitor (C1).

8. Faulty stator field winding.

9. Faulty rotor.

10. Dirty slip rings, clean slip rings when

not in use.

1. Loose connection to output stud.

2. Work not connected.

3. Electrode holder loose.

4. No open circuit voltage at output

studs. Open lead in weld circuit.

5. Faulty reactor (L1).

If all recommended possible areas

o f m i s a d j u s t m e n t h a v e b e e n

checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Summary of Contents for BULLDOG 140

Page 1: ...fore you act and be careful BULLDOG 140 For Machines with Code Number 11518 IM10005 June 2009 Various engine configurations are available and machine appearance will vary accordingly ISO 9001 CERTIFICATE NUMBER 30273 Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements QMS ANSI RAB Sales and Service through Subsidiaries and Distributor...

Page 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Page 3: ...ever simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 ii SAFETY ii FUMES AND GASES can be dangerous 5 a Welding may produce fumes...

Page 4: ...s 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 touchin...

Page 5: ...propriés et non inflamma bles 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6...

Page 6: ...ecially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at ...

Page 7: ...ion Section B Safety Instructions B 1 General Description B 1 Recommended Applications B 1 Operational Features and Controls B 1 Welding Capability B 1 Limitations B 2 Controls and Settings B 2 Gasoline Engine Conrtols Engine Operation B 3 Thru B 6 Welding Operation and Welding Guidelines B 7 Thru B 16 Accessories Section C Options Accessories C 1 Maintenance Section D Safety Precautions D 1 Routi...

Page 8: ...M 76mm x 65mm Aluminum Block with Cast Iron Sleeve Duty Cycle Amps AC Volts at Rated Amperes 30 Duty Cycle 125 Amps AC Constant Current 20 VAC 60 Duty Cycle 100 Amps AC Constant Current 25 VAC Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power 70 140 Amps AC 66 VAC Max 4000 Continuous Watts 5500 Surge Watts Height Width Depth Weight 25 47 in 21 12 in 31 48 in 205 lb 646 mm 536 45 mm 799...

Page 9: ... to an open outside area The BULLDOG 140 must be used outdoors Do not set the machine in puddles or otherwise sub merge it in water Such practices pose safety haz ards and cause improper operation and corrosion of parts Always operate the BULLDOG 140 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces and l...

Page 10: ...erate the BULLDOG 140 OIL The BULLDOG 140 is shipped with the engine filled with SAE 10W30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE This is an added precaution Do not screw in dipstick when checking oil level DO NOT OVERFILL Be sure the fill plug is tight after servicing FUEL Fill the fuel tank with clean fresh regular grade mini mum 87 octane lead free gasoline DO NOT MIX OIL WITH GAS ...

Page 11: ... rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops BULLDOG 140 OUTPUT CONNECTIONS 1 CURRENT CONTROL DIAL 2 WELD OUTPUT TERMINALS 2 3 GROUND STUD 4 CIRCUIT BREAKER 20 Amp 5 RECEPTACLE 240 VOLT 50 AMP 6 DUPLEX RECEPTACLE 2 120 VOLT 20 AMP 7 HOUR METER FIGURE A 1 1 ...

Page 12: ...nless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must 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 When the BULLDOG 140 is mounted on a truck or a trailer ...

Page 13: ...tended only for backup intermittent use power Certain electrical devices cannot be powered by the BULLDOG 140 Refer to Table A 2 for these devices CIRCUIT BREAKERS Auxiliary power is protected by circuit breakers When the machine is operated in high temperature environments the breakers may tend to trip at lower loads than normally Never bypass the circuit breakers Without over load protection the...

Page 14: ...NAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large drills well pumps grinders small current inrush for starting See refrigerators weed and hedge Table B 3 GENERATOR POWER trimmers APPLICATIONS in the OPERA TION section of this manual for required starting wattages Some synchronous motors may be frequency sensitive to attain maximum output torque but they S...

Page 15: ...th 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 outpu...

Page 16: ...the location of the following features 1 CURRENT CONTROL DIAL Adjusts continuous current output The amperages on the dial corre spond to the approximate amperages needed for specific Lincoln welding electrodes 2 20 AMP CIRCUIT BREAKER Provide separate over load current protection for the 120 Volt and 240 Volt Receptacles 3 WELD ELECTRODE OUTPUT TERMINAL Provides the connection point for the electr...

Page 17: ...in the MAINTE NANCE section of the engine owner s manual for details about the specific type of air cleaner to use 6 CHOKE Provides a richer air fuel mix ture for cold engine starting condi tions See the topic ENGINE OPERA TION below for details on setting the choke 7 RECOIL STARTER Manual rope type starter The handle position allows easy starting from either ground level or pickup truck level 8 O...

Page 18: ...4 OPERATION B 4 BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL 1 Place the machine on a level surface 2 Open the oil fill plug 3 Fill if necessary until oil flows out the top of the fill plug hole 4 Replace the fill plug and tighten securely CHECK AND FILL THE ENGINE FUEL TANK 1 Remove the fuel tank cap 2 Fill the tank to allow approximately 1 4 inch 5 mm of tank space for fuel exp...

Page 19: ...lt or 240 volt power receptacle NOTE During welding the maximum generator out put for auxiliary loads is 100 watts NOTE You can supply multiple loads as long as the total load does not exceed 5 500 surge watts or 4 000 Continuous watts Be sure to start the largest loads first CAUTION B 5 OPERATION B 5 STOPPING THE ENGINE 1 Remove all welding and generator power loads and let the engine cool by run...

Page 20: ...0 4 000 Sump Pump 600 1 500 2 400 Toaster 1 100 Weed Trimmer 500 Lincoln Wire Feeder Welder 4 000 B 6 OPERATION B 6 BULLDOG 140 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 For example a 1 HP motor requir...

Page 21: ...he desired output current 6 Start the gasoline engine See ENGINE OPERA TION in this section of the manual 7 Strike an arc and begin welding For information on welding techniques see WELDING GUIDE LINES in this section of the manual AFTER YOU FINISH THE WELD 1 Stop the gasoline engine See ENGINE OPERA TION in this section of the manual 2 Allow the electrode and work to cool completely 3 Remove the ...

Page 22: ...some Wire Feeder Welders come equipped with the essen tials needed for Gas Metal Arc Welding GMAW or MIG processes while others require the purchase of a conversion kit These products are available where Lincoln products are sold Contact your local autho rized Lincoln representative for more details B 8 OPERATION B 8 BULLDOG 140 Material Thickness Electrode Type Size Setting FLEETWELD 37 90 amps 1...

Page 23: ...uit see Figure 3 by hold ing the tip of the electrode 1 16 1 8 1 6 3 2mm away from the work or base metal being welded The electric arc is established in this gap and is held and moved along the joint to be welded melting the metal as it is moved Arc welding is a manual skill requiring a steady hand good physical condition and good eyesight The oper ator controls the welding arc and therefore the ...

Page 24: ...the electrode at a slight angle as shown in Figure 5 Figure 5 15 20 90 side view end view Correct Welding Position 2 The Correct Way to Strike An Arc Be sure the work clamp makes good electrical contact to the work Lower your headshield and scratch the electrode slowly over the metal and you will see sparks fly While scratching lift the electrode 1 8 3 2mm and the arc is established NOTE If you st...

Page 25: ...to as mild steel Typical items made with this type of steel include most sheet metal plate pipe and rolled shapes such as channels angle irons and I beams This type of steel can usually be easily welded without special precautions Some steel however contains higher carbon Typical applications include wear plates axles connecting rods shafts plowshares and scraper blades These higher carbon steels ...

Page 26: ...inal metal Successive passes must be used to build up butt welds on heavier metal Fillet Joints When welding fillet joints it is very important to hold the electrode at a 45 angle between the two sides or the metal will not distribute itself evenly To make it easier to get the 45 angle it is best to put the electrode in the holder at a 45 angle as shown Multiple Pass Welds Make multiple pass horiz...

Page 27: ... thing to watch is the molten metal As soon as it has solidi fied the arc is SLOWLY brought back and another few drops of metal are deposited DO NOT FOL LOW THE UP AND DOWN MOVEMENT OF THE ARC WITH YOUR EYES KEEP THEM ON THE MOLTEN METAL 8 When the arc is brought back to the now solidified puddle IT MUST BE SHORT otherwise no metal will be deposited the puddle will melt again and it will drip 9 It...

Page 28: ...ag A whipping technique may be used to further minimize burn through 5 If you have a choice use lap joints rather than fil lets or butts the double thickness effect of a lap joint makes it much easier to weld without burning through Hardfacing To Reduce Wear There are several kinds of wear The two most often encountered are 1 Metal to Ground Wear Plowshares bulldozer blades buckets cultivator shar...

Page 29: ... which creates brittle white cast iron The entire casting will cool slowly 2 Weld 1 2 12 7mm at a time and do not weld at that spot again until the weld is cool This way no large amount of heat is put into the mass Most inexperienced welders will probably use the sec ond method because they have no way of preheating large castings Smaller castings can easily and should be preheated before welding ...

Page 30: ... Electrodes when not used within a few hours after a container is opened must be stored in heated cabinets 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 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 Selecting Electro...

Page 31: ...ack Welding Gloves Helmet Chipping Hammer and Brush Undercarriage K2722 1 A two wheeled hand movable undercarriage is availible for field installa tion Canvas Covers K2804 1 To protect the BULL DOG 140 when not in use Made from attractive red canvas which is flame retardant mildew resistant and water repellent Rotor Removal Kit S20925 A service kit with thru and impact bolts for removing the gener...

Page 32: ...e spark plug lead before servicing the engine See the engine owner s manual for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More frequent service may be required depending on your specific application and operating conditions Table D 1 shows engine main tenance replacement parts and numbers OIL Check the oil ...

Page 33: ...cleaner 1 Wash in liquid detergent and water 2 Squeeze dry in a clean cloth 3 Saturate in clean engine oil 4 Squeeze in a clean absorbent cloth to remove all excess oil CLEAN ENGINE Remove dirt and debris with a cloth or a brush Do not clean with a forceful spray of water Water might contaminate the fuel system Periodically clean the muffler area to remove combustible debris Clean Finger Guard Are...

Page 34: ... spark plug set the terminal gap to 025 inch 65 mm with a feeler gauge See Figure D 5 FIGURE D 5 SET SPARK PLUG GAP Use the engine owner s manual for latest Plug Gap Info CLEAN SPARK ARRESTER SCREEN Refer to the engine owner s manual that was shipped with your BULLDOG 140 for the proper cleaning instructions 2 1 TABLE D 1 ENGINE MAINTENANCE PARTS FIGURE D 4 SPARK PLUG SERVICE To service spark plug...

Page 35: ...cover Item 2 RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always tight NOTE Lincoln offers a rotor removal kit for any ser vice which requires removal of the rotor from the engine See the ACCESSO...

Page 36: ...H BRUSH HOLDER ASSEMBLY AND BEARING BRACKET END COVER 5 REAR CONTROL PANEL 6 REAR PANEL ASSEMBLY 7 FUEL TANK ASSEMBLY 8 CONTROL PANEL ASSEMBLY 9 ROOF ASSEMBLY 10 SIDE PLATE 11 MUFFLER AND ENGINE 12 AIR DUCT AND FOAM 13 ENGINE END BRACKETS MACHINING 3 4 8 1 5 9 6 7 10 11 12 13 FIGURE D 7 MAJOR COMPONENT LOCATIONS ...

Page 37: ...LE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authori...

Page 38: ...le but unit will not weld 1 Disconnect anything plugged into auxiliary receptacles and weld loads 2 Open lead in flashing or field circuit 3 Open flashing diode D1 4 Faulty brushes 5 Faulty rheostat R1 6 Faulty field rectifier D1 7 Faulty capacitor C1 8 Faulty stator field winding 9 Faulty rotor 10 Dirty slip rings clean slip rings when not in use 1 Loose connection to output stud 2 Work not conne...

Page 39: ...tops running Engine sputters but will not start 1 Circuit breaker open 2 Loose or open connection with elec trical plug in component 3 Current control dial not at 140 4 No open circuit voltage at receptacle Open lead in receptacle circuit 5 No open circuit voltage at receptacle Bad receptacle 6 Rheostat R1 lead broke 1 Engine is not fully warmed up and engine choke is in the fully open RUN positio...

Page 40: ...sed 3 Low oil and engine low oil shutdown protection will not allow unit to start Light in ON OFF switch will Flash when the engine is cranked Engines equipped with low oil shut down protection only 4 Choke left in full choke position and carburetor flooded 5 Fuel line clogged or closed 6 Recoil start will not engage with engine 7 Fouled spark plug 8 Engine requires service to head head gasket and...

Page 41: ... may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 42: ...F 2 DIMENSION PRINT F 2 BULLDOG 140 M22146 A 01 6 75 29 00 31 47 NOTES N A CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK N A 21 60 25 62 7 79 9 12 13 88 ...

Page 43: ...NOTES BULLDOG 140 ...

Page 44: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 45: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 46: ...s 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 World s Leader in Welding and Cutting Products ...

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