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BULLDOG ™5500
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.
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• 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
RETURN TO MAIN MENU
For Machines with Code Number 11733
Various engine configurations are available and machine appearance will vary
accordingly.
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
February, 2011
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric BULLDOG IM10074
Summary of Contents for Lincoln Electric BULLDOG IM10074
- Page 1 BULLDOG ™5500 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...
- Page 2 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.
- Page 3 ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b.
- Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
Safety Installation ...Section A Technical Specifications...A-1 Safety Precautions ...A-2 Location and Ventilation ...A-2 Stacking, tilting and Lifting...A-3 Pre-operation Engine Service ...A-3 Oil, Fuel and Spark Arrester...A-3 Electrical Output Connections and Welding Cable Size, Lengths...A-4 Machine Grounding and Auxiliary Power Receptacles ...A-5 Premises Wiring and Circuit Breakers...A-6 Electrical Devises used with the BULLDOG™... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - bULLDOG™ 5500 K2708-2 Manufacturer Description Kohler 1 cyl., CH395 4 cycle air-cooled gasoline 9.5 HP @ 3600 RPM Aluminum Block with Cast Iron Sleeve Duty Cycle 30% Duty Cycle 60% Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges 70 - 140 Amps AC Height... -
Page 9: Safety Precautions
SAFETY PRECAUTIONS Read this entire installation section before you start installation. WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and mainte- nance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions;... -
Page 10: Pre-Operation Engine Service
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. - Page 11 bULLDOG™ 5500 OUTPUT CONNECTIONS 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.
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Page 12: Electrical Connections
• 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... -
Page 13: Circuit Breakers
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. - Page 14 Capacitive / Inductive Computers, high resolution TV sets, complicated electrical equipment. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. INSTALLATION CAUTION TAbLE A.2 Possible Concerns...
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Page 15: Operation
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;... -
Page 16: Limitations
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. -
Page 17: Engine Operation
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™... - Page 18 bEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL: 1. Place the machine on a level sur- face. 2. Open the oil fill plug. 3. Fill (if necessary) until oil flows out the top of the fill plug hole. 4.
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Page 19: Generator Operation
STOPPING THE ENGINE 1. Remove all welding and generator power loads and let the engine cool by running it for several minutes. 2. Stop the engine by placing the “ON/OFF” switch in the “OFF”(O) position. 3. Close the fuel shutoff valve. WARNING Close the fuel valve when the machine is trans- ported to prevent fuel leakage from the carburetor. - Page 20 GENERATOR POWER APPLICATIONS 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 - 1/3 HP Portable Grinder (4 1/2”) Portable Grinder (7”)
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Page 21: Welding Operation
WELDING OPERATION WARNING GENERAL INFORMATION 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. ------------------------------------------------------------------------ The BULLDOG™... - Page 22 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,...
- Page 23 No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced welder understand welding and develop his skill. For more detailed information, order a copy of the book “New Lessons in Arc Welding.”...
- Page 24 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.
- Page 25 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 the following: Mild Steel Plate: 3/16”...
- Page 26 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. 90° end view Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates.
- Page 27 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: Long arc Short arc...
- Page 28 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 A or 3/32” (2.5mm) 70 A AWS 6011 electrode on AC.
- Page 29 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 Here Brick Plow Share...
- Page 30 b-16 In some instances a back-up strip may be used and plates may be gapped 1/8” (3.2mm) or more, as shown in figure (b). Scrap steel back-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.
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Page 31: Accessories
ACCESSORIES OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your BULLDOG™ 5500 from your local Lincoln Distributor. Accessory Kit (K875) – Includes the following: • 20 Ft.(6.1m) #6 welding cable with lug. • 15 Ft.(4.6) #6 work cable with lugs. -
Page 32: Maintenance
SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to per- form maintenance and replace them when the maintenance requiring their removal is com- plete. - Page 33 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 WARNING OVERSPEED IS HAzARDOUS - The maximum allowable high idle speed for this machine is 3750 RPM, no load.
- Page 34 SPARK PLUG SERVICE Spark Plug is located between muffler and Air Cleaner. See Figure D.4. FIGURE D.4 L o c a t i o n S p a r k P l u g CAUTION • be sure not to cross thread Spark Plug when reinstalling.
- Page 35 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.
- Page 36 FIGURE D.7. - MAJOR COMPONENT LOCATIONS 1 . C R A D L E A S S E M B L Y 2 . R O T O R , B L O W E R , A N D B E A R I N G A S S E M B L Y 3 .
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Page 37: How To Use Troubleshooting Guide
HOW TO USE TROUbLESHOOTING GUIDE 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. -
Page 38: Troubleshooting
Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) No generator power or welding output. Generator power is available but unit will not weld. 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. - Page 39 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Unit will weld but low or no generator power is available. Engine runs erratically or stops running. Engine sputters but will not start. 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.
- Page 40 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Engine will not start. 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. TROUbLESHOOTING POSSIbLE CAUSE...
- Page 41 DIAGRAMS ENHANCED DIAGRAM bULLDOG™ 5500...
- Page 42 DIMENSION PRINT bULLDOG™ 5500...
- Page 43 NOTES bULLDOG™ 5500...
- Page 46 • 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...