Lincoln Electric IM10074 User Manual
Operator’s Manual
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BULLDOG ® 5500
For use with machines having Code Numbers:
11733
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Date Purchased
Code: (ex: 10859)
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IM10074 | Issue D ate .OV-1
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THANK YOU FOR SELECTING
AT ALL
TIMES.
SPECIAL SITUATIONS
Additional precautionary measures
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built with
safety in mind. However, your overall safety can be increased by
proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you
act and be careful.
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.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use
corrective lenses if necessary to
stay a reasonable distance away
from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your
face.
If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly
toxic fumes or gases.
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
SECTION A:
Diesel Engines
Gasoline Engines
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR
DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional
safety information, it is strongly recommended that you purchase a
copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the
American Welding Society, P.O. Box 351040, Miami, Florida 33135 or
CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”
booklet E205 is available from the Lincoln Electric Company, 22801
St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
SAFETY
1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts
when starting, operating or repairing
equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and welding
machines
FOR ENGINE POWERED
EQUIPMENT.
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.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
3
SAFETY
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin
or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. 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.
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:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
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.
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
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
between the
ARC RAYS CAN BURN.
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 your skin and that of your helpers from the arc rays.
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.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep 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 circumstances, outdoors, a respirator may
be required. Additional precautions are also
required when welding on galvanized steel.
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 specific
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.
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 products.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
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.
4
cause
SAFETY
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
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).
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.
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 circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and 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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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.
FOR ELECTRICALLY
POWERED EQUIPMENT.
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.
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.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety
Interactive Web Guide
for mobile devices
5
vi vi
TABLE OF CONTENTS
Page
General Description ......................................................................................................................................7
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™ 5500...................................................................A-7
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................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 Pages.....................................................................................................................P-666 Series
BULLDOG™ 5500
GENERAL DESCRIPTION
The BULLDOG™ 5500 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.
The Lincoln warranty covers the BULLDOG™ 5500 (excluding the engine) for 3 years from the date of purchase. The
engine is covered by the engine manufacturerʼs warranty
policy.
GENERAL DESCRIPTION
7
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - BULLDOG™ 5500 K2708-2
INPUT - GASOLINE ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
A-1
Kohler 1 cyl., 3750 RPM 16.9 cu. in. Manual,
CH395 4 cycle ± 100 RPM (277 cc) Recoil start;
air-cooled at no load Manual choke Oil: 1.2 qts.(1.1 L)
gasoline Bore x Stroke
8.9 HP @ 3.1” x 2.3”
3600 RPM
Aluminum Block
with Cast Iron
Sleeve
(1)
(78mm x 58mm)
Fuel: 1.9 gal. (7.2 L)
RATED OUTPUT - WELDER
Duty Cycle Amps AC Volts at Rated Amperes
30% Duty Cycle 125 Amps AC Constant Current 20 VAC
60% Duty Cycle 100 Amps AC Constant Current 25 VAC
OUTPUT - WELDER AND GENERATOR
Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power
70 - 140 Amps AC 66 VAC Max. 4000 Continuous Watts
5500 Surge Watts
PHYSICAL DIMENSIONS
Height Width Depth Weight
25.62 in. 21.77 in. 31.48 in. 198.0 lb.
651 mm 553 mm 800 mm 89.8 kg
(1)
Kohler also rates the engine at 9.5 HP@ 4000 RPM
BULLDOG™ 5500
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
WARNING
Do not attempt to use this equipment until you
have thoroughly read all the operation and maintenance manuals supplied with your machine. They
include important safety precautions; detailed
engine starting, operating, and maintenance
instructions; and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
Do not touch electrically live parts
•
or electrodes with your skin or
wet clothing.
• Insulate yourself from the work
and ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
•
Use in open, well ventilated
areas or vent exhaust to the outside.
• Do not stack anything on or near
the engine.
------------------------------------------------------------------------
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.
Only qualified personnel should install, use, or service
this equipment.
------------------------------------------------------------------------
LOCATION AND VENTILATION
Whenever you use the BULLDOG™ 5500, be sure
that clean cooling air can flow through the machineʼs
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.
The BULLDOG™ 5500 must be used outdoors. Do
not set the machine in puddles or otherwise submerge
it in water. Such practices pose safety hazards and
cause improper operation and corrosion of parts.
Always operate the BULLDOG™ 5500 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.
STORING
1. Store the machine in a cool, dry place when itʼs
not in use. Protect it from dust and dirt. Keep it
where it canʼt be accidentally damaged from construction activities, moving vehicles, and other
hazards.
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.
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.
4. While the engine is still warm, drain the oil and
refill with fresh oil per the engine manual.
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.
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™ 5500
A-3
INSTALLATION
A-3
STACKING
BULLDOG™ 5500 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The gasoline engine is designed to run in a level position 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.
LIFTING
The BULLDOG™ 5500 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
Read and understand the engine operating and
maintenance instructions supplied with this machine
before you operate the BULLDOG™ 5500.
OIL
The BULLDOG™ 5500 is shipped with the engine
filled with SAE 10W30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an
added precaution. Do not screw in dipstick when
checking oil level. DO NOT OVERFILL. Be sure the
fill plug is tight after servicing.
FUEL
Fill the fuel tank with clean, fresh, regular grade (minimum 87 octane lead free
WITH GAS. The BULLDOG™ 5500 capacity is
approximately 1.9 gallons (7.2 Liter). DO NOT OVER-
FILL, allow room in the fuel tank for fuel expansion.
gasoline. DO NOT MIX OIL
SPARK ARRESTER
Some federal, state or local laws may require gasoline
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 comes
equipped with a spark arrestor.
BULLDOG™ 5500 Typical Fuel
Consumption
Kohler CH395
WARNING
• Keep hands away from muffler or HOT engine
parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Remove fuel cap slowly to release pressure.
• Do not overfill tank.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
No Load
3750 RPM ±100 R.P.M.
AC CC Weld Output
80 Amps @ 25 Volts
Auxiliary Power 4000
Watts (120/240 Volts)
.31 Gallons/Hour
1.17 ( Liters/Hour)
.54 Gallons/Hour
2.04 ( Liters/Hour)
.74 Gallons/Hour
2.80 ( Liters/Hour)
BULLDOG™ 5500
A-4
INSTALLATION
BULLDOG™ 5500 OUTPUT CONNECTIONS
FIGURE A.1
A-4
1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
4. CIRCUIT BREAKER 20 Amp
7
1
2
6
3
5. RECEPTACLE - 240 VOLT, 20 AMP
6. DUPLEX RECEPTACLE (2)- 120 VOLT, 20
AMP
7. HOUR METER
4
5
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.
WELDING CABLE CONNECTIONS
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.
TABLE A.1
RECOMMENDED WELDING CABLE
SIZE AND LENGTH
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable
Length
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)
125 Amps
30% Duty Cycle
6 AWG
5 AWG
3 AWG
2 AWG
1 AWG
BULLDOG™ 5500
A-5
INSTALLATION
A-5
Cable Installation
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 welding cables.
2. Remove the 1/2 - 13 flanged nuts from the output
terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. You can connect either
cable to either terminal, since the BULLDOG™
5500 provides AC weld current.
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.
6. Check and tighten the connections periodically.
CAUTION
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
WARNING
1. Be grounded to the frame of the welder using a
grounded type plug.
2. Be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
-----------------------------------------------------------------------
When the BULLDOG™ 5500 is mounted on a truck or
a trailer, the machine generator ground stud MUST be
securely connected to the metal frame of the vehicle.
See Figure A.1. The ground stud is marked with the
symbol .
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
Underwriterʼs Laboratories (UL) approved double
insulation system with a two-blade plug.
Ground fault protection is recommended for hand held
equipment.
WARNING
• Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
-----------------------------------------------------------
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the ACCES-
SORIES section of this manual for more information.
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
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.)
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
Never operate this machine with damaged or
defective cords. All electrical equipment must be
in safe condition.
-----------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The control panel of the BULLDOG™ 5500 features
these three auxiliary power receptacles:
• (Two) 20 amp, 120 volt duplex (double outlet)
receptacle.
• A 20 amp 240 volt simplex (single outlet) receptacle.
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.
BULLDOG™ 5500
A-6
INSTALLATION
PREMISES WIRING
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.
Remember that the BULLDOG™ 5500 is intended
only for backup, intermittent use power.
Certain electrical devices cannot be powered by the
BULLDOG™ 5500. 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
A-6
Never bypass the circuit breakers. Without overload protection, the BULLDOG™ 5500 could overheat and/or cause damage to the equipment being
used.
------------------------------------------------------------------------
BULLDOG™ 5500
A-7
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered to this Product. See Table A.2
TABLE A.2
ELECTRICAL DEVICE USE WITH THIS PRODUCT
A-7
Type
Resistive
Capacitive
Inductive
Common Electrical Devices
Heaters, toasters, incandescent
light bulbs, electric range, hot
pan, skillet, coffee maker.
TV sets, radios, microwaves,
appliances with electrical control.
Single-phase induction motors,
drills, well pumps, grinders, small
refrigerators, weed and hedge
trimmers.
Possible Concerns
NONE
Voltage spikes or high voltage
regulation can cause the capacitative elements to fail. Surge
protection, transient protection, and
additional loading is recommended for 100% fail-safe operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
These devices require large
current inrush for starting. (See
Table B.3, GENERATOR POWER
APPLICATIONS, in the OPERATION 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
The Lincoln Electric Company is not responsible for any damage to electrical components
improperly connected to this product.
Computers, high resolution TV sets,
complicated electrical equipment.
BULLDOG™ 5500
An inductive type line conditioner along with transient and
surge protection is required,
and liabilities still exist.
DO NOT USE THESE DEVICES
WITH THIS PRODUCT.
B-1
OPERATION
B-1
SAFETY INSTRUCTIONS
Read and understand this entire section before operating
your BULLDOG™ 5500.
WARNING
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,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire
or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
RECOMMENDED APPLICATIONS
GENERATOR
The BULLDOG™ 5500 gives AC generator output for medium use, non-commercial demands. For more details on
operating the generator, see GENERATOR OPERATION in
the OPERATION section of this manual.
WELDER
The BULLDOG™ 5500 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.
OPERATIONAL FEATURES AND
CONTROLS
The BULLDOG™ 5500 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 machineʼs 70 to 125 amp range.
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 ownerʼs
manual for details about starting, running, stopping, and
breaking in the gasoline engine.
WELDING CAPABILITY
The BULLDOG™ 5500 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.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or vent
exhaust to the outside.
• Do not stack anything on or near the
engine.
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.
Only qualified personnel should install, use, or service
this equipment.
BULLDOG™ 5500
The current is continuously variable from 70 to 125 amps
AC. The BULLDOG™ 5500 can weld with all
most 1/8 inch diameter Lincoln AC electrodes.
3/32 and
B-2
OPERATION
B-2
LIMITATIONS
• The BULLDOG™ 5500 is not recommended for any
processes besides those that are normally performed using stick welding (SMAW) procedures.
• The BULLDOG™ 5500 is not recommended for
pipe thawing.
• During welding, generator power is limited to 100
watts, and output voltages can drop from 120 to 80
volts and 240 to 160 volts. Therefore, DO NOT
OPERATE ANY SENSITIVE ELECTRICAL EQUIPMENT WHILE YOU ARE WELDING.
CONTROLS AND SETTINGS
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.
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following features:
1. CURRENT CONTROL DIAL: Adjusts continuous cur-
rent output. The amperages on the dial correspond 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
the connection point for the electrode holder cable.
OUTPUT TERMINAL: Pro vides
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
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
run for maintenance purposes.
OUTPUT PANEL CONTROLS
FIGURE B.1
8
3
1
7
5
2
6
4
BULLDOG™ 5500
B-3
OPERATION
B-3
GASOLINE ENGINE CONTROLS
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™ 5500. Must be opened before you
start the engine.
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 inline fuel filter.
3. MUFFLER: Reduces engine noise output.
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.
5. AIR CLEANER: Filters intake air to the carburetor.
See ENGINE MAINTENANCE in the MAINTE-
NANCE section of the engine ownerʼs manual for
details about the specific type of air cleaner to
use.
The Kohler CH395 is equipped with a Quad clean
air filter which can be used as a warm air intake
for cold weather operation. This is done by unfastening two clips and turning the air cleaner 180°.
6. CHOKE: Provides a richer air/fuel mix-
ture for cold engine starting conditions.
See the topic ENGINE OPERATION,
below, for details on setting the choke.
7. RECOIL STARTER: Manual, rope-type starter.
The handle position allows easy starting from
either ground level or pickup-truck level
8. OIL DRAIN PLUG: Permits convenient draining of
engine oil during maintenance. Both sides of the
engine are equipped with an oil drain plug.
9. OIL FILL PLUG: Permits convenient filling of
engine oil during maintenance. Both sides of the
engine are equipped with an oil fill plug.
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed
for the BULLDOG™ 5500 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.
------------------------------------------------------------------------
Read and understand all safety instructions included
in the engine manufacturerʼs Operating and
Maintenance Instructions manual that is shipped
with the BULLDOG™ 5500.
BULLDOG™ 5500
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