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Lincoln Electric IM10074 Portable Generator User Manual

1. BULLDOG 5500 LINCOLN E MAIA INOLLOS8 v CH M NVL ALANI NI H LIM ALIAVHO 1 VN SALON E9GZZIN DIMENSION PRINT F 2 F 2 NOTES BULLDOG 5500 LINCOLN 5 Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos Donottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile od
2. A 2 Stacking tilting and Litt NG A 3 Pre operation Engine Service sise A 3 Oil Fuel and Spark Amrester eene nnne rnnt enne ns A 3 Electrical Output Connections and Welding Cable Size A 4 Machine Grounding and Auxiliary Power Receptacles A 5 Premises Wiring and Circuit Breakers enne nennen nens A 6 Electrical Devises used with the BULLDOG 5500 A 7 Section B Safety INStruCtiONS MH isa B 1 0 1 Recommended Applications sise B 1 Operational Features and Controls sr B 1 Welding Capability p Em 1 2 Gontiols and 2 Gasoline Engine Conrtols Engine Operation B 3 Thru B 6 Welding Operation and Welding Guidelines B 7 Thru B 16 EE Section C Options Accessories ie C 1 7 Section D Safety Precautions scs D 1 Routine and Periodic Maintenance nnne D 1 thru D 4 General Assembly Exploded View D 5 Troubleshooting and Repair Section E Electrical Diagram and Dimension Print Section F Parts D P 666 Series BULLDOG 5500 LINCOLN 5 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS BULLDOG 5500 2708 2 Ignition Capacities Fuel 1 9 gal 7 2 L Oil 1 2 qts 1 1 L Volts at Rated Ampe
3. ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dan gerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire TL or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 1 5 Wear eye ear and body protection 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 AN of its doors open or guards off Do not operate this equipment with any Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or service this equipment BULLDOG 5500 LINCOLN B 2 OPERATION 2 WORK OUTPUT TERMINAL Provides the connection point for the work cable GROUND STUD Provides a connection point for connecting the machine case to earth ground 240 VOLT RECEPTACLE Connection point for sup 240 Volt power to operate one electrical device 120 VOLT DUPLEX RECEPTACLES 2 Connection point for supplying 120 Volt power HOUR METER Records the time that the engine has run for maintenanc
4. The BULLDOG 5500 should be lifted by two peo ple See Specification section for weight The LowLift grab bars on both ends make lifting easi er PRE OPERATION ENGINE SERVICE Read and understand the engine operating and maintenance instructions supplied with this machine before you operate the BULLDOG 5500 A 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 Stop engine when fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel and allow fumes to clear before starting engine Do not overfill tank fuel expansion may cause overflow GASOLINE can cause fire or explosion Close fuel shut off when transporting or not operating machine BULLDOG 5500 LINCOLN 5 INSTALLATION 4 4 BULLDOG 5500 OUTPUT CONNECTIONS 5 RECEPTACLE 240 VOLT 20 AMP 6 DUPLEX RECEPTACLE 2 120 VOLT 20 AMP 7 HOUR METER TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable 125 Amps Length 30926 Duty Cycle 0 50 ft 0 15m 6 AWG 50 100 ft 15 30 m
5. 100 150 ft 30 46 m 150 200 ft 46 61 m 200 250 ft 61 76m FIGURE A 1 1 CURRENT CONTROL DIAL 2 WELD OUTPUT TERMINALS 2 3 GROUND STUD 4 CIRCUIT BREAKER 20 Amp 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 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 BULLDOG 5500 LINCOLN 8 5 INSTALLATION A 5 WARNING 1 Be grounded 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 elec
6. Shop CAUTION 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 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 A CAUTION Periodically clean the muffler area to remove com bustible debris BULLDOG 5500 LINCOLN 5 D 3 MAINTENANCE D 3 TABLE D 1 ENGINE MAINTENANCE PARTS KOHLER PART SPARK PLUG Champion RC 12YC RESISTOR GAP 030 76mm Kohler 17 083 03 S Kohler 17 083 08 S 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 Replace or clean engine maintenance parts per the interval outlined in the engine owner s manual OPERATIONAL CLEARANCE 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 restr
7. Without over load protection the BULLDOG 5500 could over heat and or cause damage to the equipment being used BULLDOG 5500 LINCOLN 5 CAUTION INSTALLATION Certain Electrical devices cannot be powered to this Product See Table A 2 ELECTRICAL DEVICE USE WITH THIS PRODUCT Possible Concerns NONE Voltage spikes or high voltage regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 10096 fail safe opera tion 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 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 An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH THIS PRODUCT TABLE A 2 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 Computers high resolution TV sets complica
8. graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan
9. 1 8 1 6 3 2mm away from the work or base metal being welded The electric arc is established in this gap and is held and moved along the joint to be welded melting the metal as it is moved Arc welding is a manual skill requiring a steady hand good physical condition and good eyesight The oper ator controls the welding arc and therefore the 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 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 FIGURE 4 The welding arc OPERATION B 9 No one c
10. A HOT ENGINE 1 Open the fuel shutoff valve 2 Place the choke lever in the RUN position Closing the choke of a hot x engine will flood the carburetor and prevent starting 3 Pull slightly on the recoil starter handle until resis tance is felt 4 Pull cord rapidly FOR BEST ENGINE STARTING Always use fresh gasoline and be sure the filter is clean and properly maintained 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 H 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 BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL 1 Place the machine on a level sur 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 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 TH
11. This is especially important on thick castings where maxi mum strength is required OPERATION B 15 4 The bead should be put on with a weaving motion and it should be 1 2 3 4 12 7 19 0mm wide Do not let the arc blow over the edge as that will dull the edge See drawing below Strike Arc Work Table H Ll ere Brick ms T 1 2 3 4 width Plow Share 12 20mm 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 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 BACKSTEPPING Backstepping greatly reduces the chances for crack ing of the share and it also greatly reduces warping 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 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 hot M A White brittle cast iron 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
12. 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 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 Hold the electrode at a slight angle as shown in Figure 5 90 side view end view Correct Welding Position Figure 5 BULLDOG 5500 LINCOLN B 11 These higher carbon steels can be weld
13. ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR LES MACHINES SOUDER partie du corps 3 Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l
14. of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Also see item 1 c Read and follow NFPA 51B St
15. 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 owner s manual for details about the specific type of air cleaner to use The Kohler 95 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 unfas tening two clips and turning the air cleaner 180 BULLDOG 5500 LINCOLN 4 OPERATION B 4 4 Pullthe 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 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 equipment can be operated FOR
16. scraper blades BULLDOG 5500 LINCOLN Fillet Joints When welding fillet joints it is very important to hold the electrode at a 45 angle between the two sides or the metal will not distribute itself evenly To make it easier to get the 45 angle it is best to put the electrode in the holder at a 45 angle as shown Multiple Pass Welds Make multiple pass 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 D pec Welding in the Vertical Position 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 OPERATION B 12 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 205 end view 90 d side view Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates Penetration Unless a weld penetrates close to 10096 a butt joint will be weaker than the material welded together 1 2 12mm 1 4 6mm 1 4 6mm In this example the total weld is only 1 2 the thi
17. 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 8 Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations 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 SAFETY WELDING and CUTTING gt 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 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 When not welding make certain no part
18. trical equipment connected to the generator recepta cles must use a three blade grounded type plug or an Underwriter s Laboratories UL approved double insulation system with a two blade plug Ground fault protection is recommended for hand held equipment A WARNING 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 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 weld ing 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 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 connec
19. 00 2 500 4 000 1 500 2 400 OPERATION TABLE 1 GENERATOR POWER APPLICATIONS Running Watts Continuous 2 000 1 250 600 1 200 1 200 1 000 500 1 000 1 500 1 250 1 200 600 2 000 500 500 700 1 500 450 100 900 2 600 50 600 200 1 000 600 1 100 500 4 000 Suggested Power Applications Air Compressor 1 HP Air Compressor 3 4 HP Airless Sprayer 1 3 HP Chain Saw Circular Saw Coffee Maker Deep Freezer Electric Motor 1 HP Electric Range 1 element Electric Skillet Furnace Fan 1 8 HP Portable Grinder 4 1 2 Portable Grinder 7 Halogen Work Light Hand Drill 1 4 Hand Drill 3 8 1500 Watt Heater Hedge Trimmer Light Bulb Reciprocating Saw Radial Arm Saw Radio Refrigerator Freezer small Slow Cooker Submersible Pump 1 HP Sump Pump Toaster Weed Trimmer Lincoln Wire Feeder Welder 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 fi
20. 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 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 You can use Table B 1 GENERATOR POWER APPLICATIONS to determine the wattage require ments of the most common types of loads you can power with the BULLDOG 5500 Be sure to read the notes at the bottom of the table TO USE THE BULLDOG 5500 AS AN AUXILIARY POWER SUPPLY 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 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 STOPPING THE ENGINE 1 Remove all welding and generator power loads and let the engine cool by running it for several m
21. BULLDOG 5500 ren 20 For Machines with Code Number 11733 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Various engine configurations are available and machine appearance will vary accordingly OPERATOR S MANUAL 150 9001 Copyright O Lincoln Global Inc LINCOLN 5 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 Designed and Manufactured Under a by SAFETY AA CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOU
22. CCESSORIES 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 Z6 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 installation Canvas Cover K2804 1 To protect the BULL DOG 5500 when not in use Made from attractive red canvas which is flame retardant mildew resistant and water repellent Rotor Removal Kit 20925 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 BULLDOG 5500 LINCOLN 8 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS OIL Check the oil level after every 5 7 hours of operation or SURE 4 WARNING TO MAINTAIN THE OIL LEVEL Change the oil the first time after 20 hours of opera tion Then under normal operating conditions change Have qualified personnel do all maintenance the oil after every 100 hours or once every 6 months and troubleshooting work whichever occurs first If the engine is operated under heavy load or in high ambient temperatures change Tur
23. E GASOLINE 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 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 1096 Ethanol and MUST be removed from the engine during storage DO NOT use gasoline containing Methanol 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 lI position FOR A COLD ENGINE 1 Open the fuel shutoff valve 2 Place the choke lever in the CHOKE x position 3 Pull slightly on the recoil starter handle until resis tance is felt BULLDOG 5500 LINCOLN 8 5 OPERATION B 5 GENERATOR OPERATION A CAUTION 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 5500 Refer to Table A 2 ELECTRICAL DEVICE USE WITH THE BULLDOG 5500 in the INSTALLATION section of this manu al GENERAL INFORMATION The BULLDOG 5500 generator is rated at 4000 continuous watts 5500 surge watts It provides both
24. LE SOURCE AND CONTROLS WORK ELECTRODE CABLE FIGURE 3 The welding circuit for Stick shielded metal arc welding BULLDOG 5500 LINCOLN 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 f 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 molt
25. NING Do not attempt use this equipment until you have thoroughly read all the operation and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e 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 out 3 side 5 AR 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 A Stop the engine before servic ing it Keep away from moving parts Only qualified personnel should install use or service this equipment BULLDOG 5500 LINCOLN 5 OIL SA 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 mini mum 87 octane lead free gasoline DO NOT MIX OIL WITH GAS The BULLDOG 5500 capacity is approximately 1 9 gallons 7 2 Liter DO NOT OVER FILL allow room in the
26. 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 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 WELDING OPERATION A WARNING GENERAL INFORMATION EI ELECTRIC SHOCK can kill Do not touch electrically live parts electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves The BULLDOG 5500 has voltage of up to 66 Volts AC which can shock The BULLDOG 5500 genera tor welder can deliver from 70 to 125 amps of continu ous welding output current Output can be adjusted by setting the current control dial on the output control panel 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 you are welding for a long time you may need to turn the dial slightly upward to mai
27. S 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 amp 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 FOR ENGINE n x 1 h Bore scalding QE the powered equipment NN y S T or pressure cap when the engine is CAE 1 8 the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND MAGNETIC FIELDS KR 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 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 vaporiz ing
28. SATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO ER SIR Chinese Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas e RIPI ERAL 54 CikHMERLEUCCF U S S SET EE E e gdo Bel yqz Sa Vae cus ll 9 Ale Viel Ai dl Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas AFFA YEARN EFREII vy Fe e gt 89 AHS HAHAE il A eh dell AS Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la ca
29. 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 weld ing use For welding the same dial selects continuous cur rent output over the machine s 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 owner s 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 6096 duty cycle The current is continuously variable from 70 to 125 amps AC The BULLDOG 5500 can weld with all 3 32 and most 1 8 inch diameter Lincoln AC electrodes 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 e
30. 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 3 Use 1 8 3 2mm Wearshield at 80 100 A Strike the arc about one inch from the sharp edge OPERATION B 14 Overhead Welding Various techniques are used for overhead welding However in the interest of simplicity for the inexperi enced welder the following technique will probably take care of his needs for overhead welding 1 Use 1 8 3 2mm 90 105 or 3 32 2 5mm 70 A AWS 6011 electrode on AC 2 Put the electrode in he holder so it sticks straight out 3 Hold the electrode at an angle approximately 30 off vertical both seen from the side and seen from end See drawing below Side View End View C 30 30 It is important to hold VERY SHORT long arc will result in falling molten metal a short arc will make the metal stay 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 Welding Sheet Metal Welding sheet metal presents an additional problem burn through Follow these simple rules 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
31. afely contact your local Lincoln Authorized Field Service Facility This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below 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 Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom A 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 5500 LINCOLN 5 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS No generator power or welding output 1 Disconnect anything plugged into auxiliary receptacles and weld loads Open lead in flashing or field circuit Open flashing diode D1 Faulty brushes Faulty rheostat R1 Faulty field rectifier D1 Faulty capacitor C1 Faulty stator field winding Faulty rotor 10 Dirty slip rings clean slip rings when not in use If all reco
32. an 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 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 ELECTRODE HOLDER WELDING MACHINE AC OR DC POWER ELECTRODE ARC Ss l N WORK CAB
33. andard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 SAFETY 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d
34. arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 5 V V for selecting a QUALITY product by Lincoln Electric We want you hank OU to take pride in operating this Lincoln Electric Company product ses as much pride as we have in bringing this product to 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 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 o
35. beza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaustao para remover fumo da zona respirat ria 450747 50 84 7 8 2 OER E 5 Fi f I8 202 e 7 5 22 0 48 Ash 71271714 552 8 HSHM 2 41 4 6 Gall bs Ja Les 5 AA ze cial ue LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR GE ZC EG CEA ECK CT ECHT ECK FEU E E E A EN EA S 15 0 o 0 SSH AUABMS ell HAY 08 58 Zeta coe eal casual QU gll ail Aal casi oig sl candy LINCOLN 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
36. ckness of the material thus the weld is only approximately half as strong as the metal Good 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 3 2mm Successive passes must be used to build up butt welds on heavier metal BULLDOG 5500 LINCOLN B 13 8 When the arc is brought back to the now solidified puddle IT MUST BE SHORT otherwise no metal will be deposited the puddle will melt again and it will drip 9 It is important to realize that the process consists of SLOW DELIBERATE movements There are no fast motions Vertical Down Welding 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 2m or 3 32 2 5mm AWS 6011 2 On thin metal use 70 75 amps 14 ga 75 A 16 ga 60 A 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 up and down whipping e short 5 motion will help prevent arc burn through on very thin plate 302 40 6 Watch the molten metal carefully The important thing is to continue lowering the
37. 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 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 manufacturer s Operating and Maintenance Instructions manual that is shipped with the BULLDOG 5500 GASOLINE ENGINE CONTROLS Refer to your engine manual for the location of the fol lowing features 1 FUEL SHUTOFF VALVE Stops the flow of gaso line from the fuel tank to the carburetor Should be closed whenever you are finished using the BULLDOG 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 in line fuel filter 3 MUFFLER Reduces engine noise
38. e A CAUTION 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 5500 LINCOLN 5 BULLDOG 5500 LINCOLN E Jequunu epoo jueuudinbe BAIN jueujeae dai e 10 207S out M si oun sourd eiunsojoue y euo uo EL y episui paysed si epoo e 104 urejBerp 5 siy Aq JO eq jou 1 Ajuo 10 S SIUL ILON 816617 AYOM STVNIWH3L Andino AA NOILISOd 9015 NMOHS H2LIMS 4 dOLS NNY voc 3NIDN3 TANVd 1 1 GNLS TWHLNAN LL J 5 gloz L7 eres x 5 ANO TANVd 1 YOLVYSNAD NO anis GNNOYD glos ue ums esee DIAGRAMS ONG O 0 L0z LOT DLOT 0 5 gon HN Moot Ka D707 oet 7 0 F 1 00SS SOCTING NVESVIC SNIHIAM
39. e brushes will seat onto the slip rings and replace bearing bracket end cover Item 2 FIGURE D 6 BRUSH REMOVAL AND REPLACEMENT BRUSH BRUSH HOLDER ASSEMBLY BEARING BRACKET END COVER STATOR END BRACKET 2 SCREWS 2 BRUSHES CABLE TIE 5 5 BULLDOG 5500 LINCOLN 5 MAINTENANCE D 5 D 5 FIGURE D 7 MAJOR COMPONENT LOCATIONS BULLDOG 5500 LINCOLN 5 CRADLE ASSEMBLY ROTOR BLOWER AND BEARING ASSEMBLY STATOR ASSEMBLY BRUSH BRUSH HOLDER ASSEMBLY AND BEARING BRACKET END COVER REAR CONTROL PANEL TOLERANCE RING BAFFLE RING CONTROL PANEL ASSEMBLY ROOF ASSEMBLY SIDE PLATE MUFFLER AND ENGINE ENDGINE END BRACKET ENGINE END BRACKETS MACHINING TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE A 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 Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action s
40. e purposes 4 LIMITATIONS The BULLDOG 5500 is not recommended for any processes besides those that are normally per formed 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 EQUIP MENT 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 OUTPUT TERMINAL Provides the connection point for the electrode holder cable OUTPUT PANEL CONTROLS FIGURE B 1 BULLDOG 5500 LINCOLN B 3 OPERATION B 3 6 CHOKE Provides a richer air fuel mix ture for cold engine starting conditions LT See the topic ENGINE OPERATION below for
41. ed are suggested settings Actual set ting may vary depending on individual preference and or specific application Beginners should use Lincoln E7018 AC 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 AWS American Welding Society A WARNING ARC RAYS can burn When using an open arc process it is necessary to use correct eye head and body protection L Semi automatic Wire Welding With a Lincoln Wire Feeder Welder The BULLDOG 5500 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 BULLDOG 5500 LINCOLN B 9 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
42. ed 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 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 Types of Welds Five types of welding joints are Butt Joints Tee Joints Lap Joints Edge Joints and Corner Joints Of these the Butt Joint and Tee Joint are the most common Butt Joint Lap Joint Edge Joint Tee Joint Corner 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 Tack the plates at both ends otherwise the heat will cause the plates to move apart See drawing B 11 PRACTICE The best way of getting practice in the four skills that enable you to maintain 1 Correct Welding Position 2 Correct Way to Strike An Arc 3 Correct Arc Length 4 Correct Welding Speed is to spend a little more time on the following exercise Use t
43. elec trode 70 A for 3 32 2 5mm electrode BULLDOG 5500 LINCOLN B 15 When breaking the weld stays on one piece To overcome this the welding operator has two choices 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 2 Weld 1 2 12 7mm at a time and do not weld at that spot again until the weld is cool This way no large amount of heat is put into the mass Most inexperienced welders will probably use the sec ond method because they have no way of preheating large castings Smaller castings can easily and should be preheated before welding A forge stove fire or the Arc Torch are all excellent means of pre heating 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 After welding Cast Iron protect the casting against fast cooling Put it in a container of warm dry sand or lime 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 Cast Iron Plate Preparation 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
44. en metal right behind the arc DO NOT WATCH THE ARC ITSELF The appearance of the puddle and the ridge where the molten solidi fies indicates correct welding speed The ridge should be approximately 3 8 9 5mm behind the electrode Ridge where puddle solidifies Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal Molten puddle 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 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 OPERATION B 10 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
45. 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 OPERATION B 13 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 Short arc NOTE Holder end of electrode is lower than arc 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 3 The arc is struck and metal deposited at the bot tom of the two pieces to be welded together 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 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 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 7 During this entire p
46. er Elektroden mit Ihrem K rper oder feuchter Kleidung e solieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e electro dos com a pele ou roupa molhada Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN O SI Chinese sole se da pe a e terra 91650080 SIE 4A 9589508988 KARHE 1 9 8 7 22 5 9 57 58 EX ATWSHRIELT FSU e f HSRMABR IMM RMR FRAIMFHRRAR 9 5585 XD 8 B oz 19 50 7 ezra He au ve 50884 AIX uie WHS Ysa nidalg 2112 AAS ASAl Jui W 2 uil gun ye AL gl dis de de L y eat lu dra pu oec SS PLI aal tog 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 ELEKTRO DENEIN
47. formation 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Safety i iv Installation Section A Technical Specifications Me nea aded en oa ed oa lee A 1 Safety Precautions issues A 2 Location and Ventilation E
48. from the engine See the ACCESSORIES section for further details 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 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 e With a jib hoist or crane lift the unit upward and remove loose cradle from engine generator assembly GENERATOR WELDER MAINTENANCE STORAGE Store the BULLDOG 5500 in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT See Figure D 6 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 4 CAUTION Do not attempt to polish slip rings while engine is running To reinstall the brushes Item 5 press them upward and slide a cable tie Item 6 through the brush hold er 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 th
49. fuel tank for fuel expansion 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 No Load 3750 RPM 100 R P M 31 Gallons Hour 1 17 Liters Hour 54 Gallons Hour 2 04 Liters Hour AC CC Weld Output 80 Amps 25 Volts 74 Gallons Hour 2 80 Liters Hour Auxiliary Power 4000 Watts 120 240 Volts GASOLINE FUEL ONLY Keep away from moving parts Do not operate with panels open or guards off Use in open well ventilated area or vent exhaust outside MOVING PARTS can injure INSTALLATION ENGINE EXHAUST can kill A 3 STACKING BULLDOG 5500 machines CANNOT be stacked TILTING Place the machine on a secure level surface whenev er you use it or store it Any surfaces you place it on other than the ground must be firm non skid and structurally sound The gasoline engine is designed to run in a level posi tion for best performance 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
50. g near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running M 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 LINCOLN 8 SAFETY ARC RAYS can burn 4 8 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 287 standards EZ 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 4 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
51. gas bad filter air cleaner spark If all recommended possible areas 8 of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility A 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 5500 LINCOLN 5 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Engine will not start Spark plug boot or wire off loose or wet Fuel shutoff valve is closed 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 Choke left in full choke position and carburetor flooded Fuel line clogged or closed Recoil start will not engage with engine Fouled spark plug If all recommended possible areas Engine requires service to head of misadjustment have been checked and the problem persists Contact your local Lincoln Float i t leak eel Authorized Field Service Facility ing from bowl Engine operated with low oil level Engine is seized and recoil start will not mov
52. he following Mild Steel Plate Electrode 3 16 4 8mm or heavier 1 8 3 2mm AWS 6011 Fleetweld 180 Current Setting 90 125 Amps AC 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 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 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 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
53. icted SPARK PLUG SERVICE Spark Plug is located between muffler and Air Cleaner See Figure D 4 FIGURE D 4 E 8 Spark Plug ad Location E sure not to cross thread Spark Plug when reinstalling This area is HOT if engine has been running Allow engine to cool before servicing B 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 solvent After cleaning or when installing a new spark plug set the terminal gap to 030 inch 76 mm with a feeler gauge See Figure D 5 FIGURE D 5 SET SPARK PLUG GAP Use the engine owner s manual for latest Plug Gap Info CLEAN SPARK ARRESTER SCREEN Refer to the engine owner s manual that was shipped with your BULLDOG 5500 for the proper cleaning instruc tions BULLDOG 5500 LINCOLN 5 D 4 MAINTENANCE D 4 RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always tight NOTE Lincoln offers a rotor removal kit for any ser vice which requires removal of the rotor
54. inutes 2 Stop the engine by placing the ON OFF switch in the OFF O position 3 Close the fuel shutoff valve A WARNING Close the fuel valve when the machine is trans ported to prevent fuel leakage from the carburetor 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 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 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 CAUTION 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 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 BULLDOG 5500 LINCOLN Start up Watts Surge 4 000 8 000 3 100 5 000 1 500 2 400 750 2 000 2 500 4 000 3 000 4 800 1 500 2 4
55. mmended possible areas of misadjustment have been checked and the problem persists Generator power is available but unit 1 Loose connection to output stud will not weld Contact your local Lincoln Authorized Field Service Facility Work not connected Electrode holder loose No open circuit voltage at output studs Open lead in weld circuit 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 5500 LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Unit will weld but low or generator 1 Circuit breaker open power is available 2 Loose or open connection with elec trical plug in component Current control dial not at 140 No open circuit voltage at receptacle Open lead in receptacle circuit No open circuit voltage at receptacle Bad receptacle 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 Engine requires service to head car buretor filters oil spark plug and or gas Engine sputters but will not start 1 Bad
56. n and corrosion of parts Always operate 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 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 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 SAFETY PRECAUTIONS Read this entire installation section before you start installation A WAR
57. n the engine off before working inside the 9 9 the oil every 25 hours 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 FIGURE D 1 OIL DRAIN AND REFILL the EXPLODED VIEW AND PARTS LIST at the LOCATION back of this manual Read the Safety Precautions in the front of this man ual and in the engine owner s manual before work ing on the BULLDOG 5500 Keep all equipment safety guards covers and devices in position and in good repair Keep your 1 OIL DRAIN PLUG hands hair clothing and tools away from the recoil 2 OILFILL PLUG housing fans and all other moving parts when start 3 OILLEVEL ing operating or repairing this machine 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 firs
58. ng 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 The Power Arc provides excellent weld output charac teristics when used in combination with Lincoln AC electrodes Other AC electrodes may also be used Follow the settings listed in Table B 2 Welding Application Guide and the Electrode Selection Guide found on the nameplate of the machine Learning To Stick Weld 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 The values list
59. ntain the same results 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 TO USE THE BULLDOG 5500 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 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 Insert the electrode into the electrode holder 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 5500 LINCOLN B 8 OPERATION B 8 WELDING GUIDELINES TABLE B 2 WELDING APPLICATIONS ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Size Setting FLEETWELD 7 90 amps AWS E6013 1 8 and thinner FLEETWELD 180 3 32 70 amps AWS E6011 Lincoln 7018 AC 90 amps AWS E7018 3 16 Maximum FLEETWELD 37 1 8 125 amps AWS E6013 5 16 Maximum FLEETWELD 180 1 8 90 amps AWS E6011 Any Thickness WEARSHIELD ABR 1 8 100 amps NOTES Stick Welding Stick weldi
60. nufacturer Also see item 1 b 5 f ELECTRIC SHOCK can kill 3 8 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 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and
61. 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Exposure to EMF fields in welding may have other health effects which are now not known 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 0 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source parts when starting operating or repairing equipment 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 workin
62. other piece has no weld on it See drawing below BULLDOG 5500 LINCOLN B 16 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 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 Low Hydrogen Group AWS E7018 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 Mo
63. r 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 Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com 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 in
64. res 20 VAC 25 VAC Manual Recoil start Manual choke INPUT GASOLINE ENGINE Speed Displacement 3750 RPM 16 9 cu in 100 RPM 277 at no load Bore x 6 3 1 x 2 3 78mm x 58mm RATED OUTPUT WELDER Amps AC 125 Amps AC Constant Current 100 Amps AC Constant Current Manufacturer Kohler CH395 Description 1 oyl 4 cycle air cooled gasoline 9 5 HP 3600 RPM Aluminum Block with Cast Iron Sleeve Duty Cycle 3096 Duty Cycle 6096 Duty Cycle OUTPUT WELDER AND GENERATOR AC Auxiliary Power 4000 Continuous Watts 5500 Surge Watts Weight 198 0 Ib 89 8 kg 31 48 in Welder Open Circuit Voltage 66 VAC Max PHYSICAL DIMENSIONS Width Depth 21 77 in 553 mm 800 mm BULLDOG 5500 LINCOLN 5 Welding Ranges 70 140 Amps AC Height 25 62 in 651 mm 2 INSTALLATION A 2 LOCATION AND VENTILATION Whenever you use the BULLDOG 5500 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 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 operatio
65. rocess 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 BULLDOG 5500 LINCOLN B 14 4 Move rapidly enough to stay ahead of the molten slag A whipping technique may be used to further minimize burn through 5 If you have a choice use lap joints rather than fil lets or butts the double thickness effect of a lap joint makes it much easier to weld without burning through Hardfacing To Reduce Wear There are several kinds of wear The two most often encountered are 1 Metal to Ground Wear Plowshares bulldozer blades buckets cultivator shares and other metal parts moving in the soil 2 Metal to Metal Wear Trunnions shafts rollers and idlers crane and mine car wheels etc Each of these types of wear demands a different kind of hardfacing electrode 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 How to Hardface the Sharp Edge Metal to Ground Wear 1 Grind the share approximately one inch along the edge so the metal is bright and clean 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
66. rst 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 z 1000 WATTS BULLDOG 5500 LINCOLN 7 B 7 7 Strike an arc and begin welding For information on welding techniques see WELDING GUIDE LINES in this section of the manual AFTER YOU FINISH THE WELD 1 Stop the gasoline engine See ENGINE OPERA TION in this section of the manual 2 Allow the electrode and work to cool completely Remove the work clamp from the work Remove any remaining piece of electrode from the electrode holder 5 f you are finished using the BULLDOG 5500 for welding disconnect the welding cables from the weld output terminals Reattach the flange nuts and leave them on the terminals NOTE 1 Welding current is continuously variable with 6096 duty cycle applying to output currents 100 Amps and less and 3096 duty cycle applying to currents above 100 Amps 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 CONTROL FUNCTION OPERATION Current Control Dial
67. 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 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 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 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 ma
68. t 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 5500 LINCOLN 5 D 2 MAINTENANCE D 2 Clean Finger Guard Area If your BULLDOG 5500 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 fin ger guard can result in overheating and damaging the engine See Figure D 2 FIGURE D 2 CLEAN AREA 1 FINGER GUARD AREA 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 FIGURE D 3 CLEAN COOLING SYSTEM 1 REMOVE DIRT AND DEBRIS FROM THIS LOWER AREA FUEL At the end of each day s use refill the fuel tank to minimize moisture condensa tion and dirt contamination in the fuel line ENGINE ADJUSTMENTS A WARNING 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 Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service
69. ted electrical equipment Type Resistive Capacitive Inductive Capacitive Inductive The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product BULLDOG 5500 LINCOLN 5 B 1 OPERATION B 1 GENERAL DESCRIPTION The BULLDOG 5500 is generator welder designed for home use and other non commercial applications As a gen erator 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 con tinuous adjustment of welding output The machine is light weight portable and can be lifted by two people The Lincoln warranty covers the BULLDOG 5500 exclud ing the engine for 3 years from the date of purchase The engine is covered by the engine manufacturer s warranty policy RECOMMENDED APPLICATIONS GENERATOR The BULLDOG 5500 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 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 CONTROLS
70. tions OPERATION B 16 In some instances a back up strip may be used and plates may be SCH 1 8 3 2mm or more as shown in figure b pu Scrap m B up strip Three ways to prepare plates where complete penetration is necessary On sections where only a sealed joint is required and strength is not important the joint may be welded after slightly veeing out the seam as shown in figure d below d 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 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 BULLDOG 5500 LINCOLN P C1 ACCESSORIES OPTIONS ACCESSORIES LINCOLN ELECTRIC A
71. tions will cause the output termi nals to overheat The terminals may eventually melt 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 BULLDOG 5500 LINCOLN 8 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 Vv CIRCUIT BREAKERS 6 0 Auxiliary power is protected by circuit breakers When the machine is operated in high temperature environ ments the breakers may tend to trip at lower loads than normally CAUTION Never bypass the circuit breakers
72. welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow

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