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IM10005
June, 2009
BULLDOG ™140
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. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Various engine configurations are available and machine appearance will vary
accordingly.
OPERATOR’S MANUAL
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
Copyright © Lincoln Global Inc.
CERTIFICATE NUMBER: 30273
• 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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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never 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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
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.
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
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.
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.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘09
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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 specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
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.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
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. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially 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 www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TABLE OF CONTENTS
Page
i-iv
Safety
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™ 140.....................................................................A-7
Operation...............................................................................................................................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
Routine and Periodic Maintenance ..............................................................................D-1 thru D-4
General Assembly Exploded View..............................................................................................D-5
Troubleshooting and Repair ................................................................................................Section E
Electrical Diagram and Dimension Print.............................................................................Section F
Parts Manual (Robin / Subaru) ......................................................................................P-615 Series
BULLDOG™ 140
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - BULLDOG™ 140 K2708-1
INPUT - GASOLINE ENGINE
Manufacturer Description
Speed
Displacement
Ignition
Capacities
Robin / Subaru
EX 30
1 cyl.,
4 cycle
air-cooled
OHC gasoline
10 HP @
3700 RPM
50 RPM
at no load
17.51 cu. in.
(287 cc)
Manual,
Recoil start;
Manual choke
Fuel: 6.86 gal. (24.9 l)
Code
(11518)
Oil: 1.1 qts.(1.0 l)
Bore x Stroke
2.95” x 2.56”
3600 RPM
Aluminum Block
with Cast Iron
Sleeve
(76mm x 65mm)
RATED OUTPUT - WELDER
Duty Cycle
30% Duty Cycle
Amps AC
125 Amps AC Constant Current
Volts at Rated Amperes
20 VAC
60% Duty Cycle
100 Amps AC Constant Current
25 VAC
OUTPUT - WELDER AND GENERATOR
Welder Open Circuit Voltage
Welding Ranges
AC Auxiliary Power
4000 Continuous Watts
5500 Surge Watts
70 - 140 Amps AC
66 VAC Max.
PHYSICAL DIMENSIONS
Height
25.47 in.
646 mm
Width
21.12 in.
Depth
31.48 in.
Weight
205 lb.
93 kg
536.45 mm
799.59 mm
BULLDOG™ 140
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
LOCATION AND VENTILATION
Read this entire installation section before you
start installation.
Whenever you use the BULLDOG™ 140, be sure that
clean cooling air can flow through the machine’s
gasoline engine and the generator. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.
WARNING
Do not attempt to use this equipment until you
have thoroughly read all the operation and main-
tenance manuals supplied with your machine.
They include important safety precautions;
detailed engine starting, operating, and mainte-
nance instructions; and parts lists.
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.
ELECTRIC SHOCK can kill.
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 live electrical
devices.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the
work and ground.
STORING
1. Store the machine in a cool, dry place when it’s
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from con-
struction activities, moving vehicles, and other
hazards.
•Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the
outside.
2. If you will be storing the machine for over 30
days, you should drain the fuel to protect fuel
system and carburetor parts from gum deposits.
Empty all fuel from the tank and run the engine
until it stops from lack of fuel.
• Do not stack anything on or
near the engine.
3. You can store the machine for up to 24 months if
you use a gasoline stabilizing additive in the fuel
system. Mix the additive with the fuel in the tank
and run the engine for a short time to circulate
the additive through the carburetor.
MOVING PARTS can injure.
• Do not operate this equip-
ment with any of its doors
open or guards off.
4. While the engine is still warm, drain the oil and
refill with fresh oil per the engine manual.
• Stop the engine before ser-
vicing it.
5. Remove the spark plug and pour approximately
1/2 ounce (15 ml) of engine oil into the cylinder.
Replace the spark plug and crank the engine
slowly to distribute the oil.
• Keep away from moving parts.
Only qualified personnel should install, use, or service
this equipment.
6. Clean any dirt and debris from the cylinder and
cylinder head fins and housing, rotating screen,
and muffler areas.
7. Store in a clean, dry area.
BULLDOG™ 140
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A-3
A-3
INSTALLATION
OIL
STACKING
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.
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.
FUEL
Fill the fuel tank with clean, fresh, regular grade (mini-
mum 87 octane lead free gasoline. DO NOT MIX OIL
WITH GAS. The BULLDOG™ 140 capacity is approxi-
mately 6.8 gallons (25.74 Liter). DO NOT OVERFILL,
allow room in the fuel tank for fuel expansion.
The gasoline engine is designed to run in a level posi-
tion for best performance. It can operate at an angle,
but this should never be more than 15 degrees in any
direction. If you do operate it at a slight angle, be sure
to check the oil regularly and keep the oil level full.
Also, fuel capacity will be a little less at an angle.
SPARK ARRESTER
LIFTING
Some federal, state or local laws may require gaso-
line engines to be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard muffler included with this machine does
qualify as a spark arrester.
The BULLDOG™ 140 should be lifted by two people.
(See Specification section for weight). The LowLift™
grab bars on both ends make lifting easier.
PRE-OPERATION ENGINE SERVICE
BULLDOG™ 140 Typical Fuel
Consumption
Read and understand the engine operating and
maintenance instructions supplied with this machine
before you operate the BULLDOG™ 140.
Robin / Subaru 10 HP Carb.
Certified EX 30
No Load
3750 RPM ±100 R.P.M.
.31 Gallons/Hour
(1.16 Liters/Hour)
WARNING
• Keep hands away from muffler or HOT engine
parts.
• Stop the engine when fueling.
AC CC Weld Output
80 Amps @ 25 Volts
.53 Gallons/Hour
(2.02 Liters/Hour)
• Do not smoke when fueling.
• Remove fuel cap slowly to release pressure.
• Do not overfill tank.
Auxiliary Power 4000
Watts (120/240 Volts)
.70 Gallons/Hour
(2.65 Liters/Hour)
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
BULLDOG™ 140
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A-4
A-4
INSTALLATION
BULLDOG™ 140 OUTPUT CONNECTIONS
FIGURE A.1
4
7
1
6
5
3
2
1. CURRENT CONTROL DIAL
5. RECEPTACLE - 240 VOLT, 50 AMP
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
6. DUPLEX RECEPTACLE (2)- 120 VOLT, 20
AMP
4. CIRCUIT BREAKER 20 Amp
7. HOUR METER
TABLE A.1
RECOMMENDED WELDING CABLE
SIZE AND LENGTH
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the current control
dial, weld output terminals, ground stud, circuit
breakers, 240 and 120 volt receptacles.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable
125 Amps
Length
30% Duty Cycle
WELDING CABLE CONNECTIONS
0-50 ft (0-15m)
50-100 ft (15-30 m)
100-150 ft (30-46 m)
150-200 ft (46-61 m)
200-250 ft (61-76m)
6 AWG
5 AWG
3 AWG
2 AWG
1 AWG
Cable Size and Length
Be sure to use welding cables that are large enough.
The correct size and length becomes especially
important when you are welding at a distance from
the welder.
Table A.1 lists recommended cable sizes and lengths
for 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
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A-5
A-5
INSTALLATION
Cable Installation
WARNING
Install the welding cables to your BULLDOG™ 140 as
follows. See Figure A.1 for the location of parts.
1. Be grounded to the frame of the welder using a
grounded type plug.
1. The gasoline engine must be OFF to install weld-
ing cables.
2. Be double insulated.
2. Remove the 1/2 - 13 flanged nuts from the output
terminals.
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, the machine generator ground stud MUST
be securely connected to the metal frame of the vehi-
cle. See Figure A.1. The ground stud is marked with
3. Connect the electrode holder and work cables to
the weld output terminals. You can connect either
cable to either terminal, since the BULLDOG™
140 provides AC weld current.
the symbol
.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding
(the “work”) is securely connected to the work
clamp and cable.
PLUGS AND HAND-HELD EQUIPMENT
For further protection against electric shock, any
electrical equipment connected to the generator
receptacles must use a three-blade, grounded type
plug or an Underwriter’s Laboratories (UL) approved
double insulation system with a two-blade plug.
6. Check and tighten the connections periodically.
CAUTION
Ground fault protection is recommended for hand
held equipment.
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
WARNING
• Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
Never operate this machine with damaged or
defective cords. All electrical equipment must be
in safe condition.
-----------------------------------------------------------
Lincoln Electric offers a welding accessory kit with
the properly specified welding cables. See the
ACCESSORIES section of this manual for more infor-
mation.
-----------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The control panel of the BULLDOG™ 140 features
two auxiliary power receptacles:
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
• A 20 amp, 120 volt duplex (double outlet) recepta-
cle
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.)
• A 20 amp 240 volt simplex (single outlet) recepta-
cle.
See Figure A.1.
Through these receptacles the machine can supply
up to 4,000 rated continuous watts and 5,500 surge
watts of single-phase AC power.
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
BULLDOG™ 140
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A-6
A-6
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.
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.
CAUTION
Never bypass the circuit breakers. Without over-
load protection, the BULLDOG™ 140 could over-
heat and/or cause damage to the equipment being
used.
-------------------------------------------------------------
BULLDOG™ 140
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A-7
A-7
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered by the BULLDOG™ 140. See Table A.2.
TABLE A.2
ELECTRICAL DEVICE USE WITH THE BULLDOG™ 140.
Type
Common Electrical Devices
Possible Concerns
Resistive
Heaters, toasters, incandescent
light bulbs, electric range, hot
pan, skillet, coffee maker.
NONE
Capacitive
TV sets, radios, microwaves,
appliances with electrical control.
Voltage spikes or high voltage
regulation can cause the capaci-
tative elements to fail. Surge
protection, transient protection,
and additional loading is recom-
mended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
Inductive
Single-phase induction motors,
drills, well pumps, grinders, small
refrigerators, weed and hedge
trimmers
These devices require large
current inrush for starting. (See
Table B.3, GENERATOR POWER
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 SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive
Computers, high resolution TV sets,
complicated electrical equipment.
An inductive type line condition-
er along with transient and
surge protection is required, and
liabilities still exist. 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.
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B-1
B-1
OPERATION
SAFETY INSTRUCTIONS
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.
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 main-
tenance manuals supplied with your machine.
They include important safety precautions;
detailed engine starting, operating, and mainte-
nance instructions; and parts lists.
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.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.
RECOMMENDED APPLICATIONS
GENERATOR
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
The BULLDOG™ 140 gives AC generator output for medi-
um use, non-commercial demands. For more details on
operating the generator, see GENERATOR OPERATION in
the OPERATION section of this manual.
FUMES AND GASES can be
dangerous.
WELDER
• Keep your head out of fumes.
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 WELDING
OPERATION in the OPERATION section of this manual.
• Use ventilation or exhaust to
remove fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
OPERATIONAL
CONTROLS
FEATURES
AND
• Keep flammable material away.
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 generator or
welding use. For welding, the same dial selects continuous
current output over the machine’s 70 to 125 amp range.
• Do not weld on containers that have
held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
The gasoline engine controls include a recoil starter, choke,
and rotary stop switch. See ENGINE OPERATION 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.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
WELDING CAPABILITY
• Do not stack anything on or near the
engine.
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 capable 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.
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.
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.
Only qualified personnel should install, use, or ser-
vice this equipment.
BULLDOG™ 140
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B-2
B-2
OPERATION
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.
4. WELD WORK OUTPUT TERMINAL: Provides the
connection point for the work cable.
5. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground.
6. 240 VOLT RECEPTACLE: Connection point for sup
• During welding, generator power is limited to 100
watts, and output voltages can drop from 120 to 80
volts and 240 to 160 volts. Therefore, DO NOT
OPERATE ANY SENSITIVE ELECTRICAL EQUIP-
MENT WHILE YOU ARE WELDING.
240 Volt power to operate one electrical device.
7. 120 VOLT DUPLEX RECEPTACLES (2): Connection
point for supplying 120 Volt power.
8. HOUR METER: Records the time that the engine has
CONTROLS AND SETTINGS
run for maintenance purposes.
All welder/generator controls are located on the Output
Control Panel. Gasoline engine controls are mounted on
the engine. See Figure B.1 and the figures in engine
operation section.
OUTPUT PANEL CONTROLS
FIGURE B.1
8
1
7
2
6
5
4
3
WELDER/GENERATOR CONTROLS
See Figure B.1 for 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 electrode holder cable.
BULLDOG™ 140
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B-3
B-3
OPERATION
GASOLINE ENGINE CONTROLS
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.
Refer to your engine manual for the location of the
following 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™ 140. Must be opened before you
start the engine.
7. RECOIL STARTER: Manual, rope-type starter.
The handle position allows easy starting from
either ground level or pickup-truck level
8. OIL DRAIN PLUG: Permits convenient draining of
engine oil during maintenance. Both sides of the
engine are equipped with an oil drain plug.
2. FUEL TANK AND CAP: See TECHNICAL SPECI-
FICATIONS for capacity.
NOTE: If you use any other alternate fuel tank or
supply, be sure to use a recommended in-
line fuel filter.
9. OIL FILL PLUG: Permits convenient filling of
engine oil during maintenance. Both sides of the
engine are equipped with an oil fill plug.
3. MUFFLER: Reduces engine noise output.
ENGINE OPERATION
WARNING
See SPARK ARRESTER in the INSTALLATION
section of this manual.
4. “ON/OFF Switch: A two position switch located
on the rear of the engine. In the “ON”(I) position,
the engine ignition circuit is energized and the
engine can be started by pulling the recoil rope
starter. In the “OFF”(O) position, the electronic
ignition is grounded and the engine shuts down.
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed
for the BULLDOG™ 140 is 3750 RPM, no load. Do
NOT adjust the governor screw on the engine.
Severe personal injury and damage to the
machine can result if it is operated at speeds
above the maximum rated speed.
5. AIR CLEANER: Filters intake air to the carburetor.
See ENGINE MAINTENANCE in the MAINTE-
NANCE section of the engine owner’s manual for
details about the specific type of air cleaner to
use.
-------------------------------------------------------------
Read and understand all safety instructions included
in the engine manufacturer’s Operating and
Maintenance Instructions manual that is shipped
with the BULLDOG™ 140.
BULLDOG™ 140
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B-4
B-4
OPERATION
4. Pull the cord rapidly.
BEFORE STARTING THE ENGINE
5. If the engine does not start, open the choke
slightly and pull the starter cord rapidly again.
CHECK AND FILL THE ENGINE OIL LEVEL:
1. Place the machine on a level
surface.
When the engine starts, gradually open the choke
to the “RUN” position. To open the choke fully
requires an engine warm-up period of several
seconds to several minutes, depending on the
temperature. After starting the engine, first open
the choke (toward RUN) until the engine just
begins to run smoothly. Then open the choke in
small steps, allowing the engine to accept small
changes in speed and load, until the choke is fully
open (in RUN). During engine warm-up the equip-
ment can be operated.
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
expansion. DO NOT FILL THE TANK
TO THE POINT OF OVERFLOW.
FOR A “HOT” ENGINE:
1. Open the fuel shutoff valve.
2. Place the choke lever in the “RUN”
position. Closing the choke of a hot
engine will flood the carburetor and
prevent starting.
3. Replace the fuel tank cap and tighten securely.
NOTE: The engine will operate satisfactorily on any
gasoline meant for automotive use. A mini-
mum of 87 octane is recommended. DO NOT
MIX OIL WITH THE GASOLINE.
3. Pull slightly on the recoil starter handle until resis-
tance is felt.
Use clean, fresh, lead-free gasoline. Leaded gasoline
may be used if lead-free is not available. However,
lead-free gasoline leaves fewer combustion deposits
and gives longer valve life. Purchase gasoline in
quantities that will be used within 30 days, to assure
freshness.
4. Pull the cord rapidly.
FOR BEST ENGINE STARTING:
• Always use fresh gasoline and be sure the filter is
clean and properly maintained.
NOTE: We DO NOT recommend using gasoline that
contains alcohol, such as gasohol. However,
if gasoline with alcohol is used, it MUST NOT
contain more than 10% Ethanol and MUST
be removed from the engine during storage.
DO NOT use gasoline containing Methanol.
• If you use an alternate fuel tank or supply, be sure
to install an in-line fuel filter.
• Do not pull the recoil starter with the
choke in the “CHOKE” position more
than one time. Repeated pulls on a
choked engine will flood the carburetor.
• If the engine will not start, see the TROU-
BLESHOOTING section of this or the engine
owner’s manual.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the gasoline
engine. Put the “ON/OFF” Switch in the
“ON”(I) position.
FOR A “COLD” ENGINE:
1. Open the fuel shutoff valve.
2. Place the choke lever in the “CHOKE”
position.
3. Pull slightly on the recoil starter handle until resis-
tance is felt.
BULLDOG™ 140
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B-5
B-5
OPERATION
STOPPING THE ENGINE
GENERATOR OPERATION
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes.
CAUTION
2. Stop the engine by placing the “ON/OFF” switch
in the “OFF”(O) position.
3. Close the fuel shutoff valve.
Be sure that any electrical equipment plugged into
the generator’s AC power receptacles can with-
stand a 10% voltage and a 4% frequency varia-
tion. Some electronic devices cannot be powered
by the BULLDOG™ 140. Refer to Table A.2, ELEC-
TRICAL DEVICE USE WITH THE BULLDOG™ 140,
in the INSTALLATION section of this manual.
WARNING
Close the fuel valve when the machine is trans-
ported to prevent fuel leakage from the carbure-
tor.
-------------------------------------------------------------
GENERAL INFORMATION
For long periods of storage, turn off the fuel shut-
off valve and let the engine run until there is no
more fuel in the line. Use a fuel additive such as
Sta-Bil to minimize fuel gum deposits.
The BULLDOG™ 140 generator is rated at 4000 con-
tinuous watts (5500 surge watts). It provides both
120 volt and 240 volt power. You can draw up to 20
amps from either side of the 120 volt duplex recepta-
cle, but no more than 33.3 amps from both sides at
once. Up to 16.7 amps can be drawn from the single
240 volt receptacle.
-------------------------------------------------------------
RUNNING THE ENGINE
The engine is set at the factory to run at high idle
speed when not under load. You should not adjust
this setting yourself.
Electrical loads in watts are approximately calculated
by multiplying the voltage rating of the load by the
number of amps it draws. (This information is given
on the load device nameplate.) For example, a
device rated 120 volts, 2 amps will need 240 watts of
power (120 x 2 = 240).
BREAK-IN PERIOD
The engine will use a greater amount of oil during its
“break-in” period. Check the oil frequently during
break-in. For more details, see the MAINTENANCE
section in the engine owner’s manual.
You can use Table B.1, GENERATOR POWER APPLI-
CATIONS, to determine the wattage requirements of
the most common types of loads you can power with
the BULLDOG™ 140. Be sure to read the notes at
the bottom of the table.
CAUTION
TO USE THE BULLDOG™ 140 AS AN AUXILIARY
POWER SUPPLY:
During break-in, the unit should be subjected to
moderate loads. Before stopping the engine,
remove all loads and allow the engine to cool sev-
eral minutes.
1. Start the gasoline engine. See ENGINE OPERA-
TION in this section of the manual and the engine
owner’s manual.
-------------------------------------------------------------
2. Set the current control dial on the output control
panel to “GENERATOR”. See Figure B.1.
LOW OIL SENSING
This engine has a built in sensor which responds to
low oil level (not pressure). When activated, the syst-
tem will shut the engine down. The engine will not
restart untill sufficient oil is added. Check oil level fre-
quently and add oil as required to the full mark on the
dipstick. (DO NOT OVERFILL)
3. Plug the load(s) into the appropriate 120 volt 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.
BULLDOG™ 140
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B-6
B-6
OPERATION
TABLE B.1
GENERATOR POWER APPLICATIONS
Suggested Power Applications
Running Watts
(Continuous)
*Start-up Watts
(Surge)
*Air Compressor - 1 HP
2,000
1,250
600
4,000 - 8,000
3,100 - 5,000
1,500 - 2,400
*Air Compressor - 3/4 HP
*Airless Sprayer - 1/3 HP
Chain Saw
1,200
1,200
1,000
500
Circular Saw
Coffee Maker
*Deep Freezer
750 - 2,000
*Electric Motor - 1 HP
Electric Range (1 element)
Electric Skillet
1,000
1,500
1,250
1,200
600
2,500 - 4,000
*Furnace Fan - 1/3 HP
Portable Grinder (4 1/2”)
Portable Grinder (7”)
Halogen Work Light
Hand Drill - 1/4”
3,000 - 4,800
2,000
500
500
Hand Drill - 3/8”
700
1500 Watt Heater
Hedge Trimmer
1,500
450
Light Bulb
100
Reciprocating Saw
Radial Arm Saw
900
2,600
50
Radio
*Refrigerator/Freezer (small)
Slow Cooker
600
1,500 - 2,400
200
*Submersible Pump - 1 HP
*Sump Pump
1,000
600
2,500 - 4,000
1,500 - 2,400
Toaster
1,100
500
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. For example a 1 HP motor requires approximately
1000 watts of power when running but may require (2.5 X 1000) = 2500 watts or (4.0 X 1000) = 4000 watts to
start.
Multiple loads can be used as long as the total load does not exceed 5,500 surge watts or 4,000 continuous
watts. Be certain to start the largest loads first.
Output rating in watts is equivalent to volt-amperes at unity power factor (resistive load) and is calculated as:
WATTS = VOLTS X AMPS DRAWN. for example a 120 volt device which is rated on its nameplate to draw 2
amps will need (120 VOLTS) X (2 AMPS) = 240 WATTS OF POWER. 1 KW = 1000 WATTS.
BULLDOG™ 140
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B-7
B-7
OPERATION
7. Strike an arc and begin welding. For information
on welding techniques, see WELDING GUIDE-
LINES in this section of the manual.
WELDING OPERATION
GENERAL INFORMATION
AFTER YOU FINISH THE WELD:
WARNING
1. Stop the gasoline engine. See ENGINE OPERA-
ELECTRIC SHOCK can kill.
TION in this section of the manual.
• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from
the electrode holder.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
5. If you are finished using the BULLDOG™ 140 for
welding, disconnect the welding cables from the
weld output terminals. Reattach the flange nuts
and leave them on the terminals.
-------------------------------------------------------------
The BULLDOG™ 140 has a voltage of up to 66 Volts
AC which can shock. The BULLDOG™ 140 genera-
tor/welder can deliver from 70 to 125 amps of contin-
uous welding output current. Output can be adjusted
by setting the current control dial on the output con-
trol panel.
NOTE: 1. Welding current is continuously variable
with 60% duty cycle applying to output
currents 100 Amps and less and 30%
duty cycle applying to currents above 100
Amps.
You can get maximum welding output by setting the
dial to 125 AMPS. At high current settings like this,
some output may decrease as the machine is used.
If you are welding for a long time, you may need to
turn the dial slightly upward to maintain the same
results.
2. Duty cycle is based on a ten minute
period. The welder can be loaded to 125
Amps for three minutes out of every ten
minute period or to 100 Amps for six
minutes out of every ten minute period.
The numbers on the dial correspond to the average
amps needed to weld using specific Lincoln welding
rods. Table B.2, WELDING APPLICATIONS, gives
you the recommended dial settings based on the
thickness of the work and the size and type of rod
you’re using.
CONTROL FUNCTION / OPERATION
“Current Control Dial”
Provides welding current adjustment from 70 through
125 Amps.
To obtain maximum weld output, turn the “Current
Control Dial” to “125 Amps” for either a cold or hot
engine. As the machine is used, some welding volt-
age may decrease at high current settings. If you are
welding for long periods of time, the dial may need to
be slightly turned upward to provide the same welding
results as when the machine was cold.
TO USE THE BULLDOG™ 140 FOR WELDING:
1. Remove the flange nuts from the weld output ter-
minals and place the work and electrode welding
cables over the terminals. (See Figure B.1)
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
The numbers listed on the dial correspond to the aver-
age amperage needed to weld specific Lincoln rods.
Refer to Table B.2 “Welding Application Guide” and
“Electrode Selection Guide” listed on the machine
nameplate for proper current and electrode settings.
2. Select the appropriate electrode. (See Table B.2)
WELDING APPLICATIONS, or the ELECTRODE
SELECTION GUIDE on the machine Output
Control Panel.
3. Attach the work clamp securely to the work you
are welding.
4. Insert the electrode into the electrode holder.
5. Set the current control dial to the desired output
current.
6. Start the gasoline engine. See ENGINE OPERA-
TION in this section of the manual.
BULLDOG™ 140
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B-8
B-8
OPERATION
WELDING GUIDELINES
TABLE B.2
WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE
Material Thickness
Electrode Type
Size
Setting
FLEETWELD® 37
1AWS E6013
90 amps
70 amps
90 amps
1/8” and thinner
FLEETWELD® 180
AWS E6011
3/32”
Lincoln 7018 AC
AWS E7018
3/16” Maximum
5/16” Maximum
Any Thickness
FLEETWELD® 37
AWS E6013
1/8”
1/8”
125 amps
90 amps
100 amps
FLEETWELD® 180
AWS E6011
WEARSHIELD® ABR
1/8”
NOTES:
Stick Welding
The values listed are suggested settings. Actual set-
ting may vary depending on individual preference
and/or specific application. Beginners should use
Lincoln E7018 AC.
Stick welding is probably the most familiar welding
process known. A coated ELECTRODE, the weld rod,
is clamped into an ELECTRODE HOLDER, an insulat-
ed clamping device, which in turn connects to the
ELECTRODE CABLE, a heavy wire. The WORK, the
metal piece to be welded, is connected to the WORK
CABLE, a heavy wire which contains the WORK
CLAMP. Quality Lincoln cables use many fine copper
wires with a very flexible insulating covering for the
electrode and work cables. When properly connected
to the OUTPUT STUDS of a high current power
source, the electrode melts and bonds the metal being
repaired. See “Cable Installation” section for proper
cable connection to a Power-Arc.
For electrodes not listed, follow tables that are
packed with the electrodes.
Ask for the Lincoln WELD DIRECTORY (Publication
C2.10) for a complete listing of all Lincoln stick elec-
trodes available.
1AWS = American Welding Society
WARNING
ARC RAYS can burn.
The Power-Arc provides excellent weld output charac-
teristics when used in combination with Lincoln AC
electrodes. Other AC electrodes may also be used.
• When using an open arc process,
it is necessary to use correct eye,
head and body protection.
-------------------------------------------------------------
Follow the settings listed in Table B.2 “Welding
Application Guide” and the “Electrode Selection
Guide” found on the nameplate of the machine.
Semi-automatic, Wire Welding With a
Lincoln Wire Feeder / Welder
Learning To Stick Weld
The BULLDOG™ 140 generator power can be used to
supply power up to 4,000 watts continuous input power
to a Lincoln Wire Feeder/Welder. The Wire
Feeder/Welder is equipped with all the supplies need-
ed for Flux-Cored Arc Welding (FCAW). Also 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.
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 vari-
ables beyond the control of The Lincoln Electric
Company affect the results obtained in applying
this type of information. These variables include,
but are not limited to, welding procedure, plate
chemistry and temperature, weldment design, fab-
rication methods and service requirements.
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B-9
B-9
OPERATION
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).
The electric arc is made between the work and the tip
end of a small metal wire, the electrode, which is
clamped in a holder that is held by the welder. A gap
is made in the welding circuit (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.
The operator’s knowledge of arc welding must go
beyond the arc itself. He must know how to control the
arc, and this requires a knowledge of the welding cir-
cuit and the equipment that provides the electric cur-
rent used in the arc. Figure 3 is a diagram of the weld-
ing circuit. The circuit begins where the electrode
cable is attached to the welding machine and ends
where the work cable cable is attached to the
machine. Current flows through the electrode cable to
the electrode holder, through the electrode holder to
the electrode and across the arc. On the work side of
the arc, the current flows through base metal to the
work cable and back to the welding machine. The cir-
cuit must be complete for the current to flow. To weld,
the work clamp must be tightly connected to clean
base metal. Remove paint, rust,etc. as necessary to
get a good connection. Connect the work clamp as
close as possible to the area you are welding. Avoid
allowing the welding circuit to pass through hinges,
bearings, electronic components or similar devices
that can be damaged.
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 quali-
ty of the weld made.
What Happens in the Arc?
Figure 4 illustrates the action that takes place in the
electric arc. It closely resembles what is actually seen
during welding.
The “arc stream” is seen in the middle of the picture.
This is the electric arc created by the electric current
flowing through the space between the end of the
electrode and the work. The temperature of this arc is
about 6000°F (3300°C) which is more than enough to
melt metal. The arc is very bright, as well as hot, and
cannot be looked at with the naked eye without risking
painful and possibly permanent injury. A very dark
lens, specifically designed for arc welding must be
used with the handshield or headshield whenever
viewing the arc.
ELECTRODE HOLDER
WELDING MACHINE
AC OR DC POWER
ELECTRODE
SOURCE AND
CONTROLS
ARC
The arc melts the base metal and actually digs into it,
much like water through a garden hose nozzle digs
into the earth. The molten metal forms a pool or crater
and tends to flow away from the arc As it moves away
from the arc, it cools and solidifies. Slag forms on top
of the weld to protect it during cooling.
WORK
WORK CABLE
Covering
Electrode
ELECTRODE CABLE
FIGURE 3 - The wellding circuit for (Stick) shielded metal arc welding.
Arc
Solidified Slag
Shielding Gases
Weld Metal
Base Metal
FIGURE 4 - The welding arc.
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B-10
B-10
OPERATION
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. The
electrode provides additional filler metal for the joint to
fill the groove or gap between the two pieces of the
base metal. The covering also melts or burns in the
arc. It has several functions. It makes the arc steadier,
provides a shield of smoke-like gas around the arc to
keep oxygen and nitrogen in the air away from the
molten metal, and provides a flux for the molten pool.
The flux picks up impurities and forms a protective
slag. The principle differences between the various
types of electrodes are in their coatings. By varying
the coating, it is possible to greatly alter the operating
characteristics of electrodes. By understanding the dif-
ferences in the various coatings, you will gain a better
understanding of selecting the best electrode for the
job you have at hand. In selecting an electrode, you
should consider:
1. The type of deposit you want, e.g., mild steel,
stainless, low alloy, hardfacing.
2. The thickness of the plate you want to weld.
3. The position it must be welded in (downhand,
out-of-position).
4. The surface condition of the metal to be welded.
5. Your ability to handle and obtain the desired
electrode.
Four simple manipulations are of prime importance.
Without complete mastery of these four, further
attempts at welding are futile. With complete mastery
of the four, welding will be easy.
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 stop moving the electrode while
scratching, the electrode will stick. Most beginners try
to strike the arc by a fast jabbing motion down on the
plate. Result: They either stick their electrode or their
motion is so fast that they break the arc immediately.
3. The Correct Arc Length
The arc length is the distance from the tip of the
electrode core wire to the base metal.
Once the arc has been established, maintaining the
correct arc length becomes extremely important. The
arc should be short, approximately 1/16 to 1/8” (1.6-
3.2mm) long. As the electrode burns off, the electrode
must be fed to the work to maintain correct arc length.
The easiest way to tell whether the arc has the correct
length is by listening to its sound. A nice, short arc has
a distinctive, “crackling” sound, very much like eggs
frying in a pan. The incorrect, long arc has a hollow,
blowing or hissing sound.
4. The Correct Welding Speed
The important thing to watch while welding is the pud-
dle of molten metal right behind the arc. DO NOT
WATCH THE ARC ITSELF. The appearance of the
puddle and the ridge where the molten puddle solidi-
fies indicates correct welding speed. The ridge should
be approximately 3/8” (9.5mm) behind the electrode.
1. The Correct Welding Position
Illustrated is the correct welding position for
right-handed people. (For left-handed people it is
opposite.)
Whenever possible, weld from left to right (if right-
handed). This enables you to see clearly what you
are doing.
Ridge where puddle
solidifies
Molten puddle
Hold the electrode at a slight angle as shown in
Figure 5.
Most beginners tend to weld too fast, resulting in a
thin, uneven, “wormy” looking bead. They are not
watching the molten metal.
15-20°
IMPORTANT: It is not generally necessary to weave
the arc forward, backward or sideways. Weld along at
a steady pace, and you will have an easier time.
90°
side view
end view
NOTE: When welding on thin plate, you will find that
you have to increase the welding speed, whereas
when welding on heavy plate, it is necessary to go
more slowly to ensure fusion and penetration.
Correct Welding Position
Figure 5
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B-11
B-11
OPERATION
These higher carbon steels can be welded successful-
ly in most cases; however, care must be taken to fol-
low proper procedures, including preheating the metal
to be welded and, in some cases, carefully controlling
the temperature during and after the welding process.
For further information on identifying various types of
steel and other metals, and for proper procedures for
welding them, we suggest you purchase a copy of
“New Lessons in Arc Welding” (See Book Division
section).
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.
Regardless of the type of metal being welded, in order
to get a quality weld, it is important that it be free of
oil, paint, rust or other contaminants.
Use the following:
Mild Steel Plate:
Electrode:
3/16” (4.8mm), or heavier.
1/8” (3.2mm) AWS 6011
(Fleetweld® 180)
Types of Welds
Current Setting:
90-125 Amps AC
Five types of welding joints are: Butt Joints, Tee
Joints, Lap Joints, Edge Joints and Corner Joints.
Do the following:
1. Learn to strike the arc by scratching the electrode
over the plate. Be sure the angle of the electrode
is right and be sure to use both hands.
Of these, the Butt Joint and Tee Joint are the most
common.
2. When you can strike an arc without sticking, prac-
tice the correct arc length. Learn to distinguish it
by its sound.
3. When you are sure that you can hold a short,
crackling arc, start moving. Look at the molten
puddle constantly, and look for the ridge where the
metal solidifies.
Butt Joint
Lap Joint
4. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and
also, it gives you an easy way to check your
progress. The 10th weld will look considerably bet-
ter than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a routine matter.
Corner Joint
Tee Joint
Edge Joint
Butt Joints
Butt Joints are the most widely used Joints. Place two
plates side by side, leaving 1/16” (1.6mm) for thin
metal to 1/8” (3.2mm) for heavy metal space between
them in order to get deep penetration.
Common Metals
Most metals found around the farm or small shop are
low carbon steel, sometimes referred 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.
Tack the plates at both ends, otherwise the heat will
cause the plates to move apart. (See drawing).
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B-12
B-12
OPERATION
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.
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.
20°
90°
end view
side view
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.
Watch the molten metal to be sure it distributes itself
evenly on both edges and in between the plates.
45°
45°
Penetration
Unless a weld penetrates close to 100%, a butt joint
will be weaker than the material welded together.
Multiple Pass Welds
1/2"
(12mm)
Make multiple pass horizontal fillets as shown in the
sketch. Put the first bead in the corner with fairly high
current. Hold the electrode angle needed to deposit
the filler beads as shown putting the final bead against
the vertical plate.
1/4"
(6mm)
Poor
1/4"
(6mm)
4
3
In this example, the total weld is only 1/2 the thickness
of the material; thus, the weld is only approximately
half as strong as the metal.
2
1
2
1
Good
Welding in the Vertical Position
In this example, the joint has been flame beveled or
ground prior to welding so that 100% penetration
could be achieved. The weld, if properly made, is as
strong or stronger than the original metal.
Welding in the vertical position can be done either
vertical-up or vertical-down. Vertical-up is used
whenever a large, strong weld is desired.
Vertical-down is used primarily on sheet metal for fast,
low penetrating welds.
60°
4
3
2
1
1/8" (3.2mm)
Successive passes must be used to build up butt
welds on heavier metal.
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B-13
B-13
OPERATION
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”.
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:
9. It is important to realize that the process consists
of SLOW, DELIBERATE movements. There are no
fast motions.
Long arc
Vertical-Down Welding
Short arc
NOTE: Holder end of electrode
is lower than arc.
Vertical-down welds are applied at a fast pace. These
welds are therefore shallow and narrow, and are
excellent for sheet metal. Do not use the vertical-down
technique on heavy metal. The welds will not be
strong enough.
1. Use 1/8” (3.2mm) 90-115 amps or 3/32” (2.5mm)
70 amps AWS 6011.
2. When welding, the electrode should be kept hori-
zontal or pointing slightly upwards. (See drawing
above).
1. Use 1/8” (3.2m) or 3/32” (2.5mm) AWS 6011.
3. The arc is struck and metal deposited at the bot-
tom of the two pieces to be welded together.
2. On thin metal use 70-75 amps.
(14 ga. 75 A - 16 ga. 60 A.)
4. Before too much molten metal is deposited, the arc
is SLOWLY moved 1/2-3/4” (12-20mm) upwards.
This takes the heat away from the molten puddle,
which solidifies. (If the arc is not taken away soon
enough, too much metal will be deposited, and it
will “drip”.)
3. Hold the electrode in a 30-45° angle with the tip of
the electrode pointing upwards.
4. Hold a VERY SHORT arc, but do not let the elec-
trode touch the metal.
Very
5. The upward motion of the arc is caused by a very
slight wrist motion. Most definitely, the arm must
not move in and out, as this makes the entire
process very complicated and difficult to learn.
5. An up and down whipping
motion will help prevent
short
arc
30°-40°
burn-through on very thin plate.
6. Watch the molten metal carefully.
6. If the upward motion of the arc is done correctly
with a wrist motion, the arc will automatically
become a long arc that deposits little or no metal.
(See drawing above.)
The important thing is to continue lowering the entire
arm as the weld is made so the angle of the electrode
does not change. Move the electrode fast enough so
that the slag does not catch up with the arc.
7. During this entire process, the ONLY 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.
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B-14
B-14
OPERATION
4. Move rapidly enough to stay ahead of the molten
slag. A whipping technique may be used to further
minimize burn through.
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:
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.
1. Use 1/8” (3.2mm) 90-105 A or 3/32” (2.5mm) 70 A
AWS 6011 electrode on AC.
Hardfacing (To Reduce Wear)
2. Put the electrode in he holder so it sticks straight
out.
There are several kinds of wear. The two most often
encountered are:
3. Hold the electrode at an angle approximately 30°
off vertical, both seen from the side and seen from
end. (See drawing below.)
1. Metal to Ground Wear: Plowshares, bulldozer
blades, buckets, cultivator shares, and other metal
parts moving in the soil.
End View
Side View
2. Metal to Metal Wear: Trunnions, shafts, rollers and
idlers, crane and mine car wheels, etc.
30°
30°
Each of these types of wear demands a different kind
of hardfacing electrode.
It is important to hold a VERY SHORT arc. (A long
arc will result in falling molten metal; a short arc will
make the metal stay.)
When applying the proper electrode, the service life of
the part will in most cases be more than double. For
instance, hardfacing of plowshares results in 3-5 times
more acreage plowed.
If necessary, and this is dictated by the appearance of
the molten puddle, a slight back and forth whipping
technique may be used to prevent “dripping”.
How to Hardface the Sharp Edge (Metal to Ground
Wear)
Welding Sheet Metal
1. Grind the share, approximately one inch along the
edge, so the metal is bright and clean.
Welding sheet metal presents an additional problem-
burn through. Follow these simple rules:
2. Place the share on an incline of approximately
20-30°. The easiest way to do this is to put one
end of the share on a brick. (See drawings) Most
users will want to hardface the underside of the
share, but some might find that the wear is on the
top side. The important thing is to hardface the
side that wears.
1. Hold a very short arc. This, together with the prop-
er travel speed, will eliminate burn through.
2. Use 1/8” (3.2mm) or 3/32” (2.5mm) AWS 6011.
3. Use low amperage. 75 A for 1/8” (3.2mm) elec-
trode, 70 A for 3/32” (2.5mm) electrode.
3. Use 1/8” (3.2mm) Wearshield at 80-100 A. Strike
the arc about one inch from the sharp edge.
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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
not let the arc blow over the edge, as that will dull
the edge. (See drawing below.)
When breaking
the weld stays on
one piece
Strike Arc
Here
Work Table
Sharp Edge
Brick
To overcome this, the welding operator has two
choices:
1/2-3/4" width
Plow Share
(12-20mm)
1. Preheat the entire casting to 500-1200°F (260-
649°C) If the cast iron is hot before welding, there
will be no sudden chilling which creates brittle
white cast iron. The entire casting will cool slowly.
Positioning of Share
Weaving Motion
5. Use the back-stepping method. Begin to weld 3”
(76mm) from the heel of the share and weld to the
heel. The second weld will begin 6” (152mm) from
the heel, the third weld 9” (229mm) from the heel,
etc.
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.
A
B
C
D
E
First weld from A to B; then
from C to A; then from D to C;
then from E to D; and so on.
3"
(75mm)
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. A forge, stove,
fire, or the Arc Torch are all excellent means of pre-
heating.
BACKSTEPPING
Backstepping greatly reduces the chances for crack-
ing of the share, and it also greatly reduces warping.
When using the 1/2” (12.7mm) at a time method, it is
recommended to start 1/2” (12.7mm) away from the
previous bead and weld into the previous bead. This
is called backstepping.
NOTE: The entire process is rather fast. Many begin-
ners go much too slowly when hardfacing plowshares,
running the risk of burning through the thin metal.
After welding Cast Iron, protect the casting against
fast cooling. Put it in a container of warm, dry sand or
lime.
Welding Cast Iron
When welding on a piece of cold cast iron, the
tremendous heat from the arc will be absorbed and
distributed rapidly into the cold mass. This heating
and sudden cooling creates WHITE, BRITTLE cast
iron in the fusion zone. (See drawing below.)
If sand or lime is not available, cover it with sheet
metal or any other non-flammable material that will
diminish drafts and retain heat.
hot
White brittle
cast iron
Cast Iron Plate Preparation
cold
cold
Wherever practical, the joint to be welded should be
“veed” out by grinding or filing to give complete pene-
tration as shown in figures (a), (b) and (c) below. This
is especially important on thick castings where maxi-
mum strength is required.
This is the reason why welds in cast iron break.
Actually, one piece of the broken cast iron has the
entire weld on it and the other piece has no weld on it.
(See drawing below.)
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B-16
B-16
OPERATION
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).
High-Speed Group (AWS E6013)
This group includes electrodes which have a moder-
ately forceful arc and deposit rates between those of
the out-of-position and high-deposit electrodes.
Scrap steel back-up strip
(b)
(c)
(a)
They are primarily general purpose production elec-
trodes especially for downhill fillets and laps or short
and irregular welds that change direction or position.
They are also widely used in maintenance and recom-
mended for sheet metal fillet and lap welds. Motion
“D” (see drawing) is generally used for vertical-up
welding, but motions “A” and “B” are also suitable.
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.
Low Hydrogen Group (AWS E7018)
(d)
(e)
These electrodes are generally called “low hydrogen”.
The name comes from the fact that their coating
contains little hydrogen in either moisture or chemical
form. Low hydrogen electrodes offer these benefits:
outstanding crack resistance, lowest porosity on
sulphur bearing steels, and X-ray quality deposit capa-
bility. Thus, they are the first choice when welding
“problem” steels. E7018 can be used in all positions,
with Motion “C” (below) recommended for the first
pass on vertical-up welds. NEVER use a whipping
technique or a long arc with these electrodes.
ALWAYS fill craters by drawing electrode away slowly.
ALWAYS keep these electrodes dry. Electrodes, when
not used within a few hours after a container is
opened, must be stored in heated cabinets.
Single and double beads, with and without
beveling for tight, partial strength joints.
Selecting Electrodes
Which electrode is best for the particular job . . . how
do you use it? These are important questions because
the cost, quality, and appearance of your work
depends on proper electrode selection and applica-
tion. MILD STEEL ELECTRODES may be classified
into the following groups:
Out-of-Position Group (AWS E6011)
This group includes electrodes which have a snappy,
deep penetrating arc and fast freezing deposits.
Motions
E
D
These electrodes are used for general purpose, all-
position fabrication and repair welding. They are also
the best choice for pipe welding and sheet metal butt,
corner, and edge welds. They can be used for repair
work when dirt, grease, plating or paint cannot be
completely cleaned from the steel. These electrodes
are typically used with motions “A” and “B” (see draw-
ing) for the first pass on vertical-up welds.
START
F
C
B
G
SIDE
VIEW
A
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C-1
C-1
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.
• 200 amp electrode holder.
• Light duty work clamp.
• Sample electrode pack.
• 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 generator rotor
from the tapered engine crankshaft.
K2819-1 Lift Bail Kit - Easily installed kit for lifting
the machine with a fixed lifting point.
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
OIL: Check the oil level after every 5
hours of operation or daily. BE SURE
TO MAINTAIN THE OIL LEVEL.
WARNING
Change the oil the first time after 20 hours of opera-
tion. Then, under normal operating conditions,
change the oil after every 100 hours or once every 6
months whichever occurs first. If the engine is oper-
ated under heavy load or in high ambient tempera-
tures, change the oil every 25 hours.
• Have qualified personnel do all maintenance
and troubleshooting work.
• Turn the engine off before working inside the
machine.
Drain the oil from the drain plug located on either side
of the engine bottom, as shown in Figure D.1. Refill
through the oil fill plug until the oil reaches the top of
the fill hole. Use the grade and viscosity recommend-
ed in the engine owner’s manual.
• Remove guards only when necessary to per-
form maintenance and replace them when the
maintenance requiring their removal is com-
plete.
• If guards are missing from the machine, get
replacements from a Lincoln Distributor. See
the EXPLODED VIEW AND PARTS LIST at the
back of this manual.
FIGURE D.1 - OIL DRAIN AND REFILL
LOCATION
-------------------------------------------------------------
Read the Safety Precautions in the front of this manu-
al and in the engine owner’s manual before working
on the BULLDOG™ 140.
2
3
1
Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep your
hands, hair, clothing, and tools away from the recoil
housing, fans, and all other moving parts when start-
ing, operating, or repairing this machine.
1. OIL DRAIN PLUG
2. OIL FILL PLUG
3. OIL LEVEL
ROUTINE AND PERIODIC
MAINTENANCE
ENGINE MAINTENANCE
CAUTION
To prevent the engine from accidentally starting,
disconnect the 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.
BULLDOG™ 140
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D-2
D-2
MAINTENANCE
FUEL: At the end of each day’s use, refill
the fuel tank to minimize moisture conden-
sation and dirt contamination in the fuel line.
Clean Finger Guard Area: If your BULLDOG™ 140 is
equipped with an engine that has a finger guard, you
should clean it as often as needed, to remove dirt or
debris that may collect on the fin areas. A dirty finger
guard can result in overheating and damaging the
engine. (See Figure D.2).
ENGINE ADJUSTMENTS
WARNING
FIGURE D.2 - CLEAN AREA
OVERSPEED IS HAZARDOUS - The maximum
allowable high idle speed for this machine is 3750
RPM, no load. DO NOT tamper with the governor
components or setting or make any other adjust-
ments to increase the maximum speed. Severe
personal injury and damage to the machine can
result if operated at speeds above maximum.
1
------------------------------------------------------------------------
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. Clean
the internal cooling fins and surfaces to prevent over-
speeding, overheating, and engine damage. Clean
every 100 operating hours or as often as necessary.
Do not use petroleum solvents such as kerosene
to clean the air cleaner. They may cause deterio-
ration of the air cleaner. DO NOT OIL THE AIR
CLEANER OR USE PRESSURIZED AIR TO CLEAN
OR DRY THE AIR CLEANER.
FIGURE D.3 - CLEAN COOLING SYSTEM
------------------------------------------------------------------------
To service the pre-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.
1
1. REMOVE DIRT AND DEBRIS FROM THIS LOWER
AREA.
CAUTION
Periodically clean the muffler area to remove
combustible debris.
------------------------------------------------------------------------
BULLDOG™ 140
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D-3
D-3
MAINTENANCE
SPARK PLUG SERVICE
To service spark plug, remove the 8 screws securing
the side panel. See Figure D.4.
Replace or clean engine maintenance parts per the
interval outlined in the engine owner’s manual.
OPERATIONAL CLEARANCE
FIGURE D.4
Approximately 12-18” of clearance should be
around this unit during operation for air flow.
Reducing this clearance will reduce air flow to the
machine causing operational temperatures to
increase. Possible damage to the machine can
result if to much air flow is restricted.
------------------------------------------------------------------------
CLEAN OR REPLACE SPARK PLUG: Clean or
replace the spark plug after every 100 hours of opera-
tion or every season, whichever comes first. Do not
blast the spark plug clean with an abrasive cleaning
device. Clean the plug by scraping it or by using a
wire brush. Wash the plug with a commercial sol-
vent. After cleaning or when installing a new 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
2
1
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.
TABLE D.1
ENGINE MAINTENANCE PARTS
PART
ROBIN / SUBARU PART #
SPARK PLUG
(RESISTOR)
Champion RL 86C
(GAP .025” [.65mm])
AIR FILTER ELEMENT
279-32612-08
Refer to Table D.1 for engine maintenance parts. The
part numbers are accurate at the time of printing.
(Verify the current part number by referring to the
engine owner’s manual.
BULLDOG™ 140
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D-4
D-4
MAINTENANCE
RECEPTACLES: Keep the electrical receptacles in
good condition. Remove any dirt, oil, or other
debris from their surfaces and holes.
GENERATOR/WELDER MAINTENANCE
STORAGE: Store the BULLDOG™ 140 in clean,
dry, protected areas.
CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always tight.
CLEANING: Blow out the generator and controls
periodically with low pressure air. Do this at least
once a week in particularly dirty areas.
NOTE: Lincoln offers a rotor removal kit for any ser-
vice which requires removal of the rotor from the
engine. See the ACCESSORIES section for further
details.
BRUSH REMOVAL AND REPLACEMENT: See
Figure D.6. It’s normal for the brushes and slip
rings to wear and darken slightly. Inspect the
brushes when a general overhaul is necessary.
Remove the brushes and clean the slip rings with
fine grit emery paper.
Removal of engine/generator assembly from the
cradle can be achieved as follows:
• Remove the two 5/16-18 hex head cap screws
from the engine block via the access hole located
in the cradle cross support channel. Leave all
other engine mountings intact.
CAUTION
Do not attempt to polish slip rings while engine
is running.
• Remove the two hex nuts from the isolator thread-
ed posts at the stator support bracket located
opposite the engine. Leave all other stator mount-
ings intact.
To reinstall the brushes (Item 5), press them upward
and slide a cable tie (Item 6) through the brush
holder tabs as shown in figure D.6. Install the brush
holder (Item 1) into the bearing end bracket (Item 3)
and secure with the screws (Item 4) previously
removed. Remove the cable tie and the brushes
will seat onto the slip rings and replace bearing
bracket end cover (Item 2).
• With a jib hoist or crane, lift the unit upward and
remove loose cradle from engine/generator
assembly.
FIGURE D.6. – BRUSH REMOVAL AND REPLACEMENT
3
1
6
2
4
5
1. BRUSH, BRUSH HOLDER ASSEMBLY
2. BEARING BRACKET END COVER
3. ENGINE END BRACKET
4. (2) SCREWS
5. (2) BRUSHES
6. CABLE TIE
BULLDOG™ 140
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D-5
D-5
MAINTENANCE
FIGURE D.7. - MAJOR COMPONENT LOCATIONS
9
7
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
8
7. FUEL TANK ASSEMBLY
8. CONTROL PANEL ASSEMBLY
9. ROOF ASSEMBLY
6
5
10. SIDE PLATE
11. MUFFLER AND ENGINE
12. AIR DUCT AND FOAM
13. ENGINE END BRACKETS MACHINING
1
12
13
4
10
11
2
3
BULLDOG™ 140
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E-1
E-1
TROUBLESHOOTING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
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.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
PROBLEMS
No generator power or welding output. 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.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Generator power is available but unit 1. Loose connection to output stud.
will not weld.
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).
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
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
PROBLEMS
Unit will weld but low or no generator 1. Circuit breaker open.
power is available.
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.
Engine runs erratically or stops running. 1. Engine is not fully warmed-up and
engine choke is in the fully open
(RUN) position.
2. Engine requires service to head, car-
buretor, filters, oil, spark plug and/or
gas.
Engine sputters but will not start.
1. Bad gas, bad filter, air cleaner, spark
plug, and/or breather.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
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
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
PROBLEMS
1. Spark plug boot or wire off, loose or
Engine will not start.
wet.
2. Fuel shutoff valve is closed.
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.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
8. Engine requires service to head,
head gasket, and/or valves.
9. Float open in carburetor & gas leak-
ing from bowl.
10. Engine operated with low oil level.
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
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F-1
F-1
DIAGRAMS
Enhanced Diagram
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F-2
F-2
DIMENSION PRINT
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NOTES
BULLDOG™ 140
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G Do not touch electrically live parts or
electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
G Keep flammable materials away.
G Wear eye, ear and body protection.
WARNING
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible
G Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
G Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
G Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
G Gardez à l’écart de tout matériel
inflammable.
G Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
G Isolez-vous du travail et de la terre.
German
G Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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G Keep your head out of fumes.
G Use ventilation or exhaust to
remove fumes from breathing zone.
G Turn power off before servicing.
G Do not operate with panel open or
guards off.
WARNING
Spanish
G Los humos fuera de la zona de res-
piración.
G Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
G Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
G No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
tien.
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
G Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
G Vermeiden Sie das Einatmen von
Schweibrauch!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
G Não opere com as tampas removidas.
G Desligue a corrente antes de fazer
serviço.
G Mantenha-se afastado das partes
moventes.
G Não opere com os paineis abertos
ou guardas removidas.
G Mantenha seu rosto da fumaça.
G Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
G Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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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