Lincoln Electric BULLDOG 5500 User manual

TECHNICAL SPECIFICATIONS - BULLDOG™ 5500 K2708-2
Manufacturer Description Speed Displacement Ignition Capacities
Kohler 1 cyl., 3750 RPM 16.9 cu. in. Manual, Fuel: 1.9 gal. (7.2 L)
CH395 4 cycle ± 100 RPM (277 cc) Recoil start;
air-cooled at no load Manual choke Oil: 1.2 qts.(1.1 L)
gasoline Bore x Stroke
8.9 HP @ 3.1” x 2.3”
3600 RPM(1) (78mm x 58mm)
Aluminum Block
with Cast Iron
Sleeve
Duty Cycle Amps AC Volts at Rated Amperes
30% Duty Cycle 125 Amps AC Constant Current 20 VAC
60% Duty Cycle 100 Amps AC Constant Current 25 VAC
Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power
70 - 140 Amps AC 66 VAC Max. 4000 Continuous Watts
5500 Surge Watts
Height Width Depth Weight
25.62 in. 21.77 in. 31.48 in. 198.0 lb.
651 mm 553 mm 800 mm 89.8 kg
A-1
INSTALLATION
BULLDOG™ 5500
A-1
INPUT - GASOLINE ENGINE
RATED OUTPUT - WELDER
OUTPUT - WELDER AND GENERATOR
PHYSICAL DIMENSIONS
(1) Kohler also rates the engine at 9.5 HP@ 4000 RPM

A-2
INSTALLATION
BULLDOG™ 5500
A-2
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
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; and parts lists.
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ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrodes with your skin or
wet clothing.
• Insulate yourself from the work
and ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
•Use in open, well ventilated
areas or vent exhaust to the out-
side.
• Do not stack anything on or near
the engine.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate this equipment
with any of its doors open or
guards off.
• Stop the engine before servic-
ing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service
this equipment.
------------------------------------------------------------------------
LOCATION AND VENTILATION
Whenever you use the BULLDOG™ 5500, be sure
that clean cooling air can flow through the machineʼs
gasoline engine and the generator. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.
The BULLDOG™ 5500 must be used outdoors. Do
not set the machine in puddles or otherwise submerge
it in water. Such practices pose safety hazards and
cause improper operation and corrosion of parts.
Always operate the BULLDOG™ 5500 with the case
roof on and all machine components completely
assembled. This will protect you from the dangers of
moving parts, hot metal surfaces, and live electrical
devices.
STORING
1. Store the machine in a cool, dry place when itʼs
not in use. Protect it from dust and dirt. Keep it
where it canʼt be accidentally damaged from 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.
WARNING

Kohler CH395
.31 Gallons/Hour
1.17 ( Liters/Hour)
.54 Gallons/Hour
2.04 ( Liters/Hour)
.74 Gallons/Hour
2.80 ( Liters/Hour)
No Load
3750 RPM ±100 R.P.M.
AC CC Weld Output
80 Amps @ 25 Volts
Auxiliary Power 4000
Watts (120/240 Volts)
BULLDOG™ 5500 Typical Fuel
Consumption
A-3
INSTALLATION
BULLDOG™ 5500
A-3
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.
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.
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PRE-OPERATION ENGINE SERVICE
Read and understand the engine operating and
maintenance instructions supplied with this machine
before you operate the BULLDOG™ 5500.
OIL
The BULLDOG™ 5500 is shipped with the engine
filled with SAE 10W30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an
added precaution. Do not screw in dipstick when
checking oil level. DO NOT OVERFILL. Be sure the
fill plug is tight after servicing.
FUEL
Fill the fuel tank with clean, fresh, regular grade (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 fuel tank for fuel expansion.
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
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.

A-4
INSTALLATION
BULLDOG™ 5500
A-4
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 OUTPUT CONNECTIONS
1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
4. CIRCUIT BREAKER 20 Amp
5. RECEPTACLE - 240 VOLT, 20 AMP
6. DUPLEX RECEPTACLE (2)- 120 VOLT, 20
AMP
7. HOUR METER
FIGURE A.1
1
2
6
7
5
3
4
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable
Length
0-50 ft (0-15m)
50-100 ft (15-30 m)
100-150 ft (30-46 m)
150-200 ft (46-61 m)
200-250 ft (61-76m)
125 Amps
30% Duty Cycle
6 AWG
5 AWG
3 AWG
2 AWG
1 AWG
TABLE A.1
RECOMMENDED WELDING CABLE
SIZE AND LENGTH

A-5
INSTALLATION
BULLDOG™ 5500
A-5
Cable Installation
Install the welding cables to your BULLDOG™ 5500
as follows. See Figure A.1 for the location of parts.
1. The gasoline engine must be OFF to install 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.
5. Be certain that the metal piece you are welding
(the “work”) is securely connected to the work
clamp and cable.
6. Check and tighten the connections periodically.
• Loose connections 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.
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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:
1. Be grounded to the frame of the welder using a
grounded type plug.
2. Be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
-----------------------------------------------------------------------
When the BULLDOG™ 5500 is mounted on a truck or
a trailer, the machine generator ground stud MUST be
securely connected to the metal frame of the vehicle.
See Figure A.1. The ground stud is marked with the
symbol .
PLUGS AND HAND-HELD EQUIPMENT
For further protection against electric shock, any elec-
trical equipment connected to the generator recepta-
cles must use a three-blade, grounded type plug or an
Underwriterʼs Laboratories (UL) approved double
insulation system with a two-blade plug.
Ground fault protection is recommended for hand held
equipment.
Never operate this machine with damaged or
defective cords. All electrical equipment must be
in safe condition.
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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.
CAUTION
WARNING
WARNING

A-6
INSTALLATION
BULLDOG™ 5500
A-6
PREMISES WIRING
The BULLDOG™ 5500 is not recommended for
premises wiring.
The BULLDOG™ 5500 does not have a combined
120/240 volt receptacle and cannot be connected to a
premises as described in other Lincoln literature.
Remember that the BULLDOG™ 5500 is intended
only for backup, intermittent use power.
Certain electrical devices cannot be powered by the
BULLDOG™ 5500. Refer to Table A.2 for these
devices.
CIRCUIT BREAKERS
Auxiliary power is protected by circuit breakers. When
the machine is operated in high temperature environ-
ments, the breakers may tend to trip at lower loads
than normally.
Never bypass the circuit breakers. Without over-
load protection, the BULLDOG™ 5500 could over-
heat and/or cause damage to the equipment being
used.
------------------------------------------------------------------------
CAUTION

A-7
INSTALLATION
BULLDOG™ 5500
A-7
CAUTION
Certain Electrical devices cannot be powered to this Product. See Table A.2
TABLE A.2
ELECTRICAL DEVICE USE WITH THIS PRODUCT
Type
Resistive
Capacitive
Inductive
Capacitive / Inductive
Common Electrical Devices
Heaters, toasters, incandescent
light bulbs, electric range, hot
pan, skillet, coffee maker.
TV sets, radios, microwaves,
appliances with electrical control.
Single-phase induction motors,
drills, well pumps, grinders, small
refrigerators, weed and hedge
trimmers.
Computers, high resolution TV sets,
complicated electrical equipment.
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 100% 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.
The Lincoln Electric Company is not responsible for any damage to electrical components
improperly connected to this product.