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Lincoln Electric IM10074 manual

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Table of contents for the manual

  • Page 1

    OPER A T OR’S MANU AL )165DI5@5>4C?>/?E Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. % $%* $)*"" %&(* %( (&( *?[...]

  • Page 2

    %($$ @?G5B545AE9@=5>D 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _____________________________[...]

  • Page 3

    (( /)31>2EB> 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. 4. b . Use suitable clothing made from durable flame-resistant material to protect [...]

  • Page 4

    %("*("" / @?G5B545AE9@=5>D 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accor[...]

  • Page 5

    9F )*/ 9F &(K+*%$))U(*K 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: )MB5DL&?EB)?E4175"WB3 1. Protegez-vous contre la[...]

  • Page 6

    F F Thank Y ou for selecting a '+"*/ 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! (514D89C%@5B1D?BC #1>E1<3?=@<5D5<I before attempting to use this equipment. Save this manual and ke[...]

  • Page 7

    Page Safety i-iv Installation ............................................................................................................................. Section A Technical Specifications ..............................................................................................................A-1 Safety Precautions ..........................[...]

  • Page 8

    *$" )& *%$)+""%O! #1>E613DEB5B 5C3B9@D9?> )@554 9C@<135=5>D 7>9D9?> 1@139D95C Kohler 1 cyl., 3750 RPM 16.9 cu. in. Manual, Fuel: 1.9 gal. (7.2 L) CH395 4 cycle ± 100 RPM (277 cc) Recoil start; air-c[...]

  • Page 9

     $)* "" *%$ +""%O  )*/ &(+*%$) (514D89C5>D9B59>CD1<<1D9?>C53D9?>256?B5I?E CD1BD9>CD1<<1D9?> ? >?D 1DD5=@D D? EC5 D89C 5AE9@=5>D E>D9< I?E 81F5D[...]

  • Page 10

    !?8<5B .31 Gallons/Hour 1.17 ( Liters/Hour) .54 Gallons/Hour 2.04 ( Liters/Hour) .74 Gallons/Hour 2.80 ( Liters/Hour) No Load 3750 RPM ±100 R.P.M. AC CC Weld Output 80 Amps @ 25 Volts Auxiliary Power 4000 Watts (120/240 Volts) +""%O * I@931<E5< ?>CE=@D9?>  $)* [...]

  • Page 11

     $)* "" *%$ +""%O  ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit break- ers, 240 and 120 volt receptacles. -"$"%$$*%$) 12&l[...]

  • Page 12

     $)* "" *%$ +""%O  12<5>CD1<<1D9?> Install the welding cables to your BULLDOG™ 5500 as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install weld- ing cables. 2. Remove the 1/2 - 13 flanged nuts fro[...]

  • Page 13

     $)* "" *%$ +""%O  &(#))-($ The BULLDOG™ 5500 is not recommended for premises wiring. The BULLDOG™ 5500 does not have a combined 120/240 volt receptacle and cannot be connected to a premises as described in other Lincoln literature. Remem[...]

  • Page 14

     $)* "" *%$ +""%O  +*%$ Certain Electrical devices cannot be powered to this Product. See Table A.2 *" "*(",+)-**)&(%+* *I@5 Resistive Capacitive Ind[...]

  • Page 15

     %&( *%$  SAFETY INSTRUCTIONS Read and understand this entire section before operating your BULLDOG™ 5500. Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, ope[...]

  • Page 16

     %&( *%$  LIMIT A TIONS • The BULLDOG™ 5500 is not recommended for any p r o ce s s e s b e s i d e s t h o s e t h a t a r e n o r m a ll y p e r - formed using stick welding (SMAW) procedures. • The BULLDOG™ 5500 is not recommended for pipe thawing. • During welding, generator power is limited to 100 watts[...]

  • Page 17

     %&( *%$  +""%O )%"$$$%$*(%") Refer to your engine manual for the location of the fol- lowing features: 1. FUEL SHUTOFF VALVE: Stops the flow of gaso- line from the fuel tank to the carburetor. Should be closed whenever you are finished using[...]

  • Page 18

    4. Pull the cord rapidly. 5. If the engine does not start, open the choke slight- ly and pull the starter cord rapidly again. 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 sec- onds to several minutes, depending on the tem- perature. After starting th[...]

  • Page 19

    $( * %(%&( *%$ 5CEB5 D81D1>I5<53DB931<5AE9@=5>D @<E77549>D? D85 75>5B1D?BWC  @?G5B B535@D13<5C 31> G9D8 CD1>4 1 P F?<D175 1>4 1 P 6B5AE5>3I F1B91 D9?>  )?=5 5<53DB?>93?[...]

  • Page 20

    *" $(*%(&%-(&&"*%$) )E775CD54&?G5B@@<931D9?>C (E>>9>7-1DDC )D1BDE@-1DDC ?>D9>E?EC)EB75 *Air Compressor - [...]

  • Page 21

     %&( *%$  WELDING OPERA TION $("$%(# *%$ "*()%!31>;9<< N ? >?D D?E38 5<53DB931<<I <9F5 @1BDC ?B 5<53DB?45C G9D8 I?EB C;9> ?B G5D 3<?D8 9>7 N>CE<1D5[...]

  • Page 22

    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.[...]

  • Page 23

     %&( *%$  +""%O 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.?[...]

  • Page 24

     %&( *%$  +""%O 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 m[...]

  • Page 25

      %&( *%$   +""%O &(* 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 followin[...]

  • Page 26

     %&( *%$  +""%O 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. Watch the molten metal to be sure it distributes itself even[...]

  • Page 27

     %&( *%$  +""%O ,5BD931<+@-5<49>7 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 techni[...]

  • Page 28

     %&( *%$  +""%O %F5B8514-5<49>7 Various techniques are used for overhead welding. However, in the interest of simplicity for the inexperi- enced welder, the following technique will probably take care of his needs for overhead welding: 1. Use 1/8” (3.2mm) 90-105 A or [...]

  • Page 29

     %&( *%$  +""%O 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.) 5. Use the back-stepping method. Begin to weld 3” (76mm) from the heel of[...]

  • Page 30

     %&( *%$  +""%O 978)@554B?E@-) 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. They are primarily general purpose production elec- [...]

  • Page 31

     ))%()  OPTIONS/ACCESSORIES "$%"$"*( ))%() The following options/accessories are available for your BULLDOG™ 5500 from your local Lincoln Distributor. Accessory Kit (K875) – Includes the following: • 20 Ft.(6.1m) #6 welding cable with lug. • 15 F[...]

  • Page 32

     #$*$$  +""%O )*/ &(+*%$) N 1F5 AE1<96954 @5BC?>>5< 4? 1<< =19>D5>1>35 1>4DB?E2<5C8??D9>7G?B; N*EB> D85 5>79>5 ?66 256?B5 G?B;9>7 9>C945?[...]

  • Page 33

     #$*$$  +"  At the end of each day’s use, refill the fuel tank to minimize moisture condensa- tion and dirt contamination in the fuel line. $$  +)*#$*) %,()& ) 0(%+)  *85 =1H9=E= 1<<?G12<5 8978 94<5[...]

  • Page 34

    )& (!&"+)(, Spark Plug is located between muffler and Air Cleaner. See Figure D.4. N  5 CEB5 >?D D? 3B?CC D8B514 )@1B; &<E7 G85> B59>CD1<<9>7 N  *89C 1B51 9C %* 96 5>79>5 81C 255> BE>>9>7 <<?G[...]

  • Page 35

     #$*$$  +""%O $( *%(-"(#$*$$ )*%( Store the BULLDOG™ 5500 in clean, dry, protected areas. "$$ Blow out the generator and controls periodically with low pressure air. Do this at least once a wee[...]

  • Page 36

     #$*$$  +""%O 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. TOLERANCE RING 7. BAFFLE RING 8. CONTROL PANEL ASSEMBLY 9. ROOF ASSEMBLY 10. SIDE PLATE 11. MUFFLER AN[...]

  • Page 37

    +""%O  *(%+")%%*$  If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "?31<"9>3?<>ED8?B9J5495<4)5BF935139<9DI for technical troubleshooting assistance[...]

  • Page 38

     *(%+")%%*$  +""%O Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "?31<"9>3?<>ED8?B9J5495<4)5[...]

  • Page 39

     *(%+")%%*$  +""%O Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "?31<"9>3?<>ED8?B9J5495<4)5[...]

  • Page 40

     *(%+")%%*$  +""%O Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your "?31<"9>3?<>ED8?B9J5495<4)5[...]

  • Page 41

     (#)  +""%O $%* This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Departm[...]

  • Page 42

     #$)%$&($*  +""%O M22563 A.02 NOTES: N.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK. 14.17  .41HOLE (4 PLACES) 17.50 BOTTOM VIEW 21.77 25.62 6.78 8.44 31.48 8.38 15.00 N.A. M 22 5 6 3 A .02 NOTES: N.A. CENTER OF G RAVITY W ITH OIL IN ENGINE AND EMPTY FUEL TA[...]

  • Page 43

    $%*) +""%O[...]

  • Page 44

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇ Ã O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INS TR UCTION FOR THIS EQUIPMENT AND THE CONSUMABLES T O BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABRI[...]

  • Page 45

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