Lincoln Electric Portable Generator IM10074 User Manual

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IM10074  
February, 2011  
BULLDOG 5500  
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.  
AL  
OR’S MANU  
AT  
OPER  
ISO 9001  
ANSI RAB  
QMS  
Designed and Manufactured Under aꢀ  
Quality Program Certified byꢀ  
ABS Quality Evaluations, Inc.ꢀ  
to ISO 9001 Requirements.  
Copyright © Lincoln Global Inc.  
CERTIFICATE NUMBER: 30273  
• 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 WEBꢀSITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
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.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
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.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
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 manufacturer.  
5.f. Also see item 1.b.  
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SAFETY  
WELDING and CUTTING  
SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
process used and properly operating  
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.  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
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.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
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SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
PRÉCAUTIONS DE SÛRETÉ  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
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:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
b. Faire trés 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 couché pour lesquelles une  
grande partie du corps peut être en contact avec la  
masse.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment toxique) ou autres produits irritants.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se pro-  
téger contre les chutes dans le cas ou on recoit un choc. Ne  
jamais enrouler le câble-électrode autour de n’importe quelle  
partie du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du  
rayonnement de l’arc et des projections quand on soude  
ou quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code  
de l’électricité et aux recommendations du fabricant. Le dis-  
positif de montage ou la piece à souder doit être branché à  
une bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste  
seront effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflamma-  
bles.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection  
libres de l’huile, tels que les gants en cuir, chemise épaisse,  
pantalons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank 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 no 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 or 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.  
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 information 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 WEbꢀSITE 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:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
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TABLE OF CONTENTS  
Page  
i-iv  
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™ 5500...................................................................A-7  
Operation...............................................................................................................................Section B  
Safety Instructions.......................................................................................................................B-1  
General Description.....................................................................................................................B-1  
Recommended Applications........................................................................................................B-1  
Operational Features and Controls .............................................................................................B-1  
Welding Capability.......................................................................................................................B-1  
Limitations .................................................................................................................................B-2  
Controls and Settings..................................................................................................................B-2  
Gasoline Engine Conrtols, Engine Operation...............................................................B-3 Thru B-6  
Welding Operation and Welding Guidelines...............................................................B-7 Thru B-16  
Accessories...........................................................................................................................Section C  
Options/Accessories ...................................................................................................................C-1  
Maintenance..........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-1  
Routine and Periodic Maintenance ...............................................................................D-1 thru D-4  
General Assembly Exploded View..............................................................................................D-5  
Troubleshooting and Repair ................................................................................................Section E  
Electrical Diagram and Dimension Print.............................................................................Section F  
Parts Pages.....................................................................................................................P-666 Series  
bULLDOG™ 5500  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - bULLDOG™ 5500 K2708-2  
INPUT - GASOLINE ENGINE  
Manufacturer Description  
Speed  
Displacement  
Ignition  
Capacities  
Kohler  
CH395  
1 cyl.,  
4 cycle  
air-cooled  
gasoline  
3750 RPM  
± 100 RPM  
at no load  
16.9 cu. in.  
(277 cc)  
Manual,  
Recoil start;  
Manual choke  
Fuel: 1.9 gal. (7.2 L)  
Oil: 1.2 qts.(1.1 L)  
bore x Stroke  
3.1” x 2.3”  
(78mm x 58mm)  
9.5 HP @  
3600 RPM  
Aluminum Block  
with Cast Iron  
Sleeve  
RATED OUTPUT - WELDER  
Duty Cycle  
30% Duty Cycle  
Amps AC  
125 Amps AC Constant Current  
Volts at Rated Amperes  
20 VAC  
60% Duty Cycle  
100 Amps AC Constant Current  
25 VAC  
OUTPUT - WELDER AND GENERATOR  
Welder Open Circuit Voltage  
Welding Ranges  
AC Auxiliary Power  
4000 Continuous Watts  
5500 Surge Watts  
70 - 140 Amps AC  
66 VAC Max.  
PHYSICAL DIMENSIONS  
Height  
25.62 in.  
651 mm  
Width  
21.77 in.  
553 mm  
Depth  
31.48 in.  
800 mm  
Weight  
198.0 lb.  
89.8 kg  
bULLDOG™ 5500  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
LOCATION AND VENTILATION  
Read this entire installation section before you  
start installation.  
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.  
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; and parts lists.  
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.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
or electrodes with your skin or  
wet clothing.  
STORING  
• Insulate yourself from the work  
and ground.  
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.  
•Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
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.  
• Use in open, well ventilated  
areas or vent exhaust to the out-  
side.  
• Do not stack anything on or near  
the engine.  
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.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
• Do not operate this equipment  
with any of its doors open or  
guards off.  
4. While the engine is still warm, drain the oil and  
refill with fresh oil per the engine manual.  
• Stop the engine before servic-  
ing it.  
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.  
• Keep away from moving parts.  
Only qualified personnel should install, use, or service  
this equipment.  
6. Clean any dirt and debris from the cylinder and  
cylinder head fins and housing, rotating screen,  
and muffler areas.  
------------------------------------------------------------------------  
7. Store in a clean, dry area.  
bULLDOG™ 5500  
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A-3  
A-3  
INSTALLATION  
OIL  
STACKING  
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.  
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.  
FUEL  
Fill the fuel tank with clean, fresh, regular grade (mini-  
mum 87 octane lead free gasoline. DOꢀNOTꢀMIX OIL  
WITHꢀGAS. 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.  
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.  
SPARK ARRESTER  
LIFTING  
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.  
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  
bULLDOG™ 5500 Typical Fuel  
Consumption  
Read and understand the engine operating and  
maintenance instructions supplied with this machine  
before you operate the BULLDOG™ 5500.  
Kohler CH395  
No Load  
3750 RPM ±100 R.P.M.  
.31 Gallons/Hour  
1.17 ( Liters/Hour)  
WARNING  
• Keep hands away from muffler or HOT engine  
parts.  
• Stop the engine when fueling.  
AC CC Weld Output  
80 Amps @ 25 Volts  
.54 Gallons/Hour  
2.04 ( Liters/Hour)  
• 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.  
Auxiliary Power 4000  
Watts (120/240 Volts)  
.74 Gallons/Hour  
2.80 ( Liters/Hour)  
• Keep sparks and flame away from tank.  
------------------------------------------------------------------------  
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A-4  
A-4  
INSTALLATION  
bULLDOG™ 5500 OUTPUT CONNECTIONS  
FIGURE A.1  
2
3
7
1
6
4
5
4
7
1
6
5
3
2
1. CURRENT CONTROL DIAL  
5. RECEPTACLE - 240 VOLT, 20 AMP  
6. DUPLEX RECEPTACLE (2)- 120 VOLT, 20  
AMP  
7. HOUR METER  
2. WELD OUTPUT TERMINALS (2)  
3. GROUND STUD  
4. CIRCUIT bREAKER 20 Amp  
TAbLE A.1  
RECOMMENDED WELDING CAbLE  
SIzE AND LENGTH  
ELECTRICAL OUTPUT  
CONNECTIONS  
TOTAL COMbINED LENGTH OF  
ELECTRODE AND WORK CAbLES  
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.  
Cable  
Length  
125 Amps  
30% Duty Cycle  
WELDING CAbLE CONNECTIONS  
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)  
6 AWG  
5 AWG  
3 AWG  
2 AWG  
1 AWG  
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.  
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A-5  
INSTALLATION  
Cable Installation  
WARNING  
1. be grounded to the frame of the welder using a  
grounded type plug.  
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. be double insulated.  
Do not ground the machine to a pipe that carries  
explosive or combustible material.  
2. Remove the 1/2 - 13 flanged nuts from the output  
terminals.  
-----------------------------------------------------------------------  
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  
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.  
symbol  
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.  
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  
Underwriter’s Laboratories (UL) approved double  
insulation system with a two-blade plug.  
6. Check and tighten the connections periodically.  
CAUTION  
Ground fault protection is recommended for hand held  
equipment.  
• Loose connections will cause the output termi-  
nals to overheat. The terminals may eventually  
melt.  
WARNING  
• Do not cross the welding cables at the output  
terminal connection. Keep the cables isolated  
and separate from one another.  
Never operate this machine with damaged or  
defective cords. All electrical equipment must be  
in safe condition.  
-----------------------------------------------------------  
Lincoln Electric offers a welding accessory kit with the  
-----------------------------------------------------------  
AUXILIARY POWER RECEPTACLES  
properly specified welding cables. See the ACCES-  
The control panel of the BULLDOG™ 5500 features  
these three auxiliary power receptacles:  
SORIES section of this manual for more information.  
ELECTRICAL CONNECTIONS  
MACHINE GROUNDING  
• (Two) 20 amp, 120 volt duplex (double outlet)  
receptacle.  
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.)  
• 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.  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
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A-6  
INSTALLATION  
PREMISES WIRING  
The BULLDOG™ 5500 is not recommended for  
premises wiring.  
The BULLDOG™ 5500 does not have a combined  
120/240 volt receptacle and cannot be connected to a  
premises as described in other Lincoln literature.  
Remember that the BULLDOG™ 5500 is intended  
only for backup, intermittent use power.  
Certain electrical devices cannot be powered by the  
BULLDOG™ 5500. Refer to Table A.2 for these  
devices.  
CIRCUIT bREAKERS  
Auxiliary power is protected by circuit breakers. When  
the machine is operated in high temperature environ-  
ments, the breakers may tend to trip at lower loads  
than normally.  
CAUTION  
Never bypass the circuit breakers. Without over-  
load protection, the BULLDOG™ 5500 could over-  
heat and/or cause damage to the equipment being  
used.  
------------------------------------------------------------------------  
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A-7  
A-7  
INSTALLATION  
CAUTION  
Certain Electrical devices cannot be powered to this Product. See Table A.2  
TAbLE A.2  
ELECTRICAL DEVICE USE WITH THIS PRODUCT  
Type  
Possible Concerns  
Common Electrical Devices  
Resistive  
NONE  
Heaters, toasters, incandescent  
light bulbs, electric range, hot  
pan, skillet, coffee maker.  
Capacitive  
Voltage spikes or high voltage  
regulation can cause the capac-  
itative elements to fail. Surge  
TV sets, radios, microwaves,  
appliances with electrical control.  
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.  
Inductive  
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.)  
Single-phase induction motors,  
drills, well pumps, grinders, small  
refrigerators, weed and hedge  
trimmers.  
Some synchronous motors may  
be frequency sensitive to attain  
maximum output torque, but  
they SHOULD BE SAFE from  
any frequency induced failures.  
Capacitive / Inductive  
An inductive type line condition-  
er along with transient and  
surge protection is required,  
and liabilities still exist.  
Computers, high resolution TV sets,  
complicated electrical equipment.  
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.  
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b-1  
OPERATION  
SAFETY INSTRUCTIONS  
Read and understand this entire section before operating  
your BULLDOG™ 5500.  
GENERAL DESCRIPTION  
The BULLDOG™ 5500 is a 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.  
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.  
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.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
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.  
• 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.  
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.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
WELDING SPARKS can cause fire  
or explosion.  
OPERATIONAL  
CONTROLS  
FEATURES  
AND  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
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.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
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.  
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.  
WELDING CAPABILITY  
The BULLDOG™ 5500 is rated 125 amps, 20 volts at 30%  
duty cycle on a ten-minute basis. This means that you can  
load the welder to 125 amps for three minutes out of every  
ten-minute period. The machine is also capable of higher  
duty cycles at lower output currents. You can load the  
welder to 100 amps for six minutes out of ten for a 60% duty  
cycle.  
MOVING PARTS can injure.  
• Do not operate this equipment with any  
of its doors open or guards off.  
• Stop the engine before servicing it.  
• Keep away from moving parts.  
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.  
Only qualified personnel should install, use, or service  
this equipment.  
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OPERATION  
4. WELD WORK OUTPUT TERMINAL: Provides the  
LIMITATIONS  
connection point for the work cable.  
• 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.  
5. GROUND STUD: Provides a connection point for  
connecting the machine case to earth ground.  
6. 240 VOLT RECEPTACLE: Connection point for sup  
240 Volt power to operate one electrical device.  
• During welding, generator power is limited to 100  
watts, and output voltages can drop from 120 to 80  
7. 120 VOLT DUPLEX RECEPTACLES (2): Connection  
point for supplying 120 Volt power.  
volts and 240 to 160 volts. Therefore, DO NOT  
OPERATE ANY SENSITIVE ELECTRICAL EQUIP-  
MENT WHILE YOU ARE WELDING.  
8. HOUR METER: Records the time that the engine has  
run for maintenance purposes.  
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  
3
5
4
8
1
7
2
6
8
1
7
2
6
5
4
3
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b-3  
OPERATION  
GASOLINE ENGINE CONTROLS  
6. CHOKE: Provides a richer air/fuel mix-  
ture for cold engine starting conditions.  
See the topic ENGINE OPERATION,  
below, for details on setting the choke.  
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.  
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.  
2. FUEL TANK AND CAP: See TECHNICALꢀSPECI-  
FICATIONS for capacity.  
9. OIL FILL PLUG: Permits convenient filling of  
engine oil during maintenance. Both sides of the  
engine are equipped with an oil fill plug.  
NOTE: If you use any other alternate fuel tank or  
supply, be sure to use a recommended in-  
line fuel filter.  
ENGINE OPERATION  
3. MUFFLER: Reduces engine noise output.  
See SPARK ARRESTER in the INSTALLATION  
section of this manual.  
WARNING  
4. “ON/OFF Switch: A two position switch located on  
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.  
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.  
Read and understand all safety instructions included  
in the engine manufacturer’s Operating and  
The Kohler CH395 is equipped with a Quad clean  
air filter which can be used as a warm air intake  
for cold weather operation. This is done by unfas-  
tening two clips and turning the air cleaner 180°.  
Maintenance Instructions manual that is shipped  
with the BULLDOG™ 5500.  
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OPERATION  
4. Pull the cord rapidly.  
bEFORE STARTING THE ENGINE  
5. If the engine does not start, open the choke slight-  
ly and pull the starter cord rapidly again.  
CHECK AND FILL THE ENGINE OIL LEVEL:  
1. Place the machine on a level sur-  
face.  
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.  
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.  
FOR A “HOT” ENGINE:  
1. Open the fuel shutoff valve.  
2. Place the choke lever in the “RUN”  
position. Closing the choke of a hot  
engine will flood the carburetor and  
prevent starting.  
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 THE GASOLINE.  
3. Pull slightly on the recoil starter handle until resis-  
tance is felt.  
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.  
4. Pull the cord rapidly.  
FOR bEST ENGINE STARTING:  
• Always use fresh gasoline and be sure the filter is  
clean and properly maintained.  
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 10% Ethanol and MUST be  
removed from the engine during storage. DO  
NOT use gasoline containing Methanol.  
• If 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  
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.  
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”(I) position.  
FOR A “COLD” ENGINE:  
1. Open the fuel shutoff valve.  
2. Place the choke lever in the “CHOKE”  
position.  
3. Pull slightly on the recoil starter handle until resis-  
tance is felt.  
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OPERATION  
STOPPING THE ENGINE  
GENERATOR OPERATION  
1. Remove all welding and generator power loads  
and let the engine cool by running it for several  
minutes.  
CAUTION  
2. Stop the engine by placing the “ON/OFF” switch in  
the “OFF”(O) position.  
3. Close the fuel shutoff valve.  
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.  
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.  
------------------------------------------------------------------------  
GENERAL INFORMATION  
The BULLDOG™ 5500 generator is rated at 4000  
continuous watts (5500 surge watts). It provides both  
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.  
------------------------------------------------------------------------  
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  
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).  
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.  
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.  
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.  
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.  
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)  
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.  
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OPERATION  
TAbLE b.1  
GENERATOR POWER APPLICATIONS  
Suggested Power Applications  
Running Watts  
(Continuous)  
*Start-up Watts  
(Surge)  
*Air Compressor - 1 HP  
2,000  
1,250  
600  
4,000 - 8,000  
3,100 - 5,000  
1,500 - 2,400  
*Air Compressor - 3/4 HP  
*Airless Sprayer - 1/3 HP  
Chain Saw  
1,200  
1,200  
1,000  
500  
Circular Saw  
Coffee Maker  
*Deep Freezer  
750 - 2,000  
*Electric Motor - 1 HP  
Electric Range (1 element)  
Electric Skillet  
1,000  
1,500  
1,250  
1,200  
600  
2,500 - 4,000  
*Furnace Fan - 1/3 HP  
Portable Grinder (4 1/2”)  
Portable Grinder (7”)  
Halogen Work Light  
Hand Drill - 1/4”  
3,000 - 4,800  
2,000  
500  
500  
Hand Drill - 3/8”  
700  
1500 Watt Heater  
Hedge Trimmer  
1,500  
450  
Light Bulb  
100  
Reciprocating Saw  
Radial Arm Saw  
900  
2,600  
50  
Radio  
*Refrigerator/Freezer (small)  
Slow Cooker  
600  
1,500 - 2,400  
200  
*Submersible Pump - 1 HP  
*Sump Pump  
1,000  
600  
2,500 - 4,000  
1,500 - 2,400  
Toaster  
1,100  
500  
Weed Trimmer  
Lincoln Wire Feeder/Welder  
4,000  
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 first.  
Output rating in watts is equivalent to volt-amperes at unity power factor (resistive load) and is calculated as:  
WATTS = VOLTSꢀ X ꢀAMPSꢀDRAWN. for example a 120 volt device which is rated on its nameplate to draw 2  
amps will need (120 VOLTS) X (2 AMPS) = 240 WATTSꢀOFꢀPOWER. 1 KW = 1000 WATTS.  
bULLDOG™ 5500  
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OPERATION  
7. Strike an arc and begin welding. For information  
on welding techniques, see WELDING GUIDE-  
LINES in this section of the manual.  
WELDING OPERATION  
WARNING  
AFTER YOU FINISH THE WELD:  
GENERAL INFORMATION  
1. Stop the gasoline engine. See ENGINE OPERA-  
TION in this section of the manual.  
ELECTRIC SHOCK can kill.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
4. Remove any remaining piece of electrode from  
the electrode holder.  
• Insulate yourself from the work and ground.  
• Always wear dry insulating gloves.  
5. If 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.  
------------------------------------------------------------------------  
The BULLDOG™ 5500 has a 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.  
NOTE: 1. Welding current is continuously variable  
with 60% duty cycle applying to output  
currents 100 Amps and less and 30%  
duty cycle applying to currents above 100  
Amps.  
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. If  
you are welding for a long time, you may need to turn  
the dial slightly upward to maintain the same results.  
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.  
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.  
CONTROL FUNCTION / OPERATION  
“Current Control Dial”  
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.  
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.  
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.  
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.  
4. Insert the electrode into the electrode holder.  
5. 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.  
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OPERATION  
WELDING GUIDELINES  
TAbLE b.2  
WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE  
Material Thickness  
Electrode Type  
Size  
Setting  
FLEETWELD® 37  
1AWSꢀE6013  
90 amps  
70 amps  
90 amps  
1/8” and thinner  
FLEETWELD® 180  
AWSꢀE6011  
3/32”  
Lincoln 7018 AC  
AWSꢀE7018  
3/16” Maximum  
5/16” Maximum  
Any Thickness  
FLEETWELD® 37  
AWS E6013  
1/8”  
1/8”  
125 amps  
90 amps  
100 amps  
FLEETWELD® 180  
AWS E6011  
WEARSHIELD® ABR  
1/8”  
NOTES:  
Stick Welding  
The values listed are suggested settings. Actual set-  
ting may vary depending on individual preference  
and/or specific application. Beginners should use  
Lincoln E7018 AC.  
Stick welding is probably the most familiar welding  
process known. A coated ELECTRODE, the weld rod,  
is clamped into an ELECTRODEꢀHOLDER, an insulat-  
ed clamping device, which in turn connects to the  
ELECTRODEꢀCABLE, 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 STUDSꢀof 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.  
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.  
1AWS = American Welding Society  
WARNING  
ARC RAYS can burn.  
The Power-Arc provides excellent weld output charac-  
teristics when used in combination with Lincoln AC  
electrodes. Other AC electrodes may also be used.  
• When using an open arc process,  
it is necessary to use correct eye,  
head and body protection.  
------------------------------------------------------------------------  
Follow the settings listed in Table B.2 “Welding  
Application Guide” and the “Electrode Selection  
Guide” found on the nameplate of the machine.  
Semi-automatic, Wire Welding With a  
Lincoln Wire Feeder / Welder  
Learning To Stick Weld  
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.  
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.  
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OPERATION  
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.” (See Book Division section at rear of manual).  
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 - 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.  
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.  
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.  
ELECTRODE HOLDER  
WELDING MACHINE  
AC OR DC POWER  
ELECTRODE  
SOURCE AND  
CONTROLS  
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.  
WORK  
WORK CABLE  
Covering  
Electrode  
ELECTRODE CABLE  
FIGURRE 3 - TThhe weldding circuit for (Stick) shielded metal arc welding.  
Arc  
Solidified Slag  
Shielding Gases  
Weld Metal  
Base Metal  
FIGURE 4 - The welding arc.  
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OPERATION  
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, 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.  
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: If 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 molten metal right behind the arc. DOꢀNOT  
WATCHꢀTHEꢀARCꢀITSELF. The appearance of the  
puddle and the ridge where the molten puddle solidi-  
fies indicates correct welding speed. The ridge should  
be approximately 3/8” (9.5mm) behind the electrode.  
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.  
Ridge where puddle  
solidifies  
Molten puddle  
Hold the electrode at a slight angle as shown in  
Figure 5.  
Most beginners tend to weld too fast, resulting in a  
thin, uneven, “wormy” looking bead. They are not  
watching the molten metal.  
15-20°  
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.  
90°  
side view  
end view  
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.  
Correct Welding Position  
Figure 5  
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OPERATION  
These higher carbon steels can be welded 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).  
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.  
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.  
Use the following:  
Mild Steel Plate:  
Electrode:  
3/16” (4.8mm), or heavier.  
1/8” (3.2mm) AWS 6011  
(Fleetweld® 180)  
Types of Welds  
Current Setting:  
90-125 Amps AC  
Five types of welding joints are: Butt Joints, Tee  
Joints, Lap Joints, Edge Joints and Corner Joints.  
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.  
Of these, the Butt Joint and Tee Joint are the most  
common.  
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.  
Butt Joint  
Lap Joint  
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.  
Corner Joint  
Tee Joint  
Edge 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.  
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  
scraper blades.  
Tack the plates at both ends, otherwise the heat will  
cause the plates to move apart. (See drawing).  
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OPERATION  
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.  
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.  
20°  
90°  
end view  
side view  
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.  
Watch the molten metal to be sure it distributes itself  
evenly on both edges and in between the plates.  
45°  
45°  
Penetration  
Unless a weld penetrates close to 100%, a butt joint  
will be weaker than the material welded together.  
Multiple Pass Welds  
1/2"  
(12mm)  
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.  
1/4"  
(6mm)  
Poor  
1/4"  
(6mm)  
4
3
In this example, the total weld is only 1/2 the thickness  
of the material; thus, the weld is only approximately  
half as strong as the metal.  
2
1
2
1
Good  
Welding in the Vertical Position  
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.  
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.  
60°  
4
3
2
1
1/8" (3.2mm)  
Successive passes must be used to build up butt  
welds on heavier metal.  
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OPERATION  
8. When the arc is brought back to the now solidified  
puddle, ITꢀMUSTꢀBEꢀSHORT, otherwise no metal  
will be deposited, the puddle will melt again, and it  
will “drip”.  
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:  
9. It is important to realize that the process consists  
of SLOW, DELIBERATE movements. There are no  
fast motions.  
Long arc  
Vertical-Down Welding  
Short arc  
NOTE: Holder end of electrode  
is lower than arc.  
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” (3.2mm) 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).  
1. Use 1/8” (3.2m) or 3/32” (2.5mm) AWS 6011.  
3. The arc is struck and metal deposited at the bot-  
tom of the two pieces to be welded together.  
2. On thin metal use 70-75 amps.  
(14 ga. 75 A - 16 ga. 60 A.)  
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”.)  
3. Hold the electrode in a 30-45° angle with the tip of  
the electrode pointing upwards.  
4. Hold a VERYꢀSHORT arc, but do not let the elec-  
trode touch the metal.  
Very  
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.  
5. An up and down whipping  
motion will help prevent  
burn-through on very thin plate.  
short  
arc  
30°-40°  
6. Watch the molten metal carefully.  
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.)  
The important thing is to continue lowering the 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.  
7. During this entire process, 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. DOꢀNOTꢀ FOL-  
LOW THE UP AND DOWN MOVEMENT OF THE  
ARC WITH YOUR EYES. KEEP THEM ON THE  
MOLTEN METAL.  
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OPERATION  
4. Move rapidly enough to stay ahead of the molten  
slag. A whipping technique may be used to further  
minimize burn through.  
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:  
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.  
1. Use 1/8” (3.2mm) 90-105 A or 3/32” (2.5mm) 70 A  
AWS 6011 electrode on AC.  
Hardfacing (To Reduce Wear)  
2. Put the electrode in he holder so it sticks straight  
out.  
There are several kinds of wear. The two most often  
encountered are:  
3. Hold the electrode at an angle approximately 30°  
off vertical, both seen from the side and seen from  
end. (See drawing below.)  
1. Metal to Ground Wear: Plowshares, bulldozer  
blades, buckets, cultivator shares, and other metal  
parts moving in the soil.  
End View  
Side View  
2. Metal to Metal Wear: Trunnions, shafts, rollers and  
idlers, crane and mine car wheels, etc.  
30°  
30°  
Each of these types of wear demands a different kind  
of hardfacing electrode.  
It is important to hold a VERYꢀSHORT arc. (A long  
arc will result in falling molten metal; a short arc will  
make the metal stay.)  
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.  
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”.  
How to Hardface the Sharp Edge (Metal to Ground  
Wear)  
Welding Sheet Metal  
1. Grind the share, approximately one inch along the  
edge, so the metal is bright and clean.  
Welding sheet metal presents an additional problem-  
burn through. Follow these simple rules:  
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 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.  
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) elec-  
trode, 70 A for 3/32” (2.5mm) electrode.  
3. Use 1/8” (3.2mm) Wearshield at 80-100 A. Strike  
the arc about one inch from the sharp edge.  
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b-15  
b-15  
OPERATION  
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.)  
When breaking  
the weld stays on  
one piece  
Strike Arc  
Here  
Work Table  
Sharp Edge  
Brick  
To overcome this, the welding operator has two  
choices:  
1/2-3/4" width  
Plow Share  
(12-20mm)  
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.  
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.  
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.  
A
B
C
D
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.  
3"  
(75mm)  
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.  
BACKSTEPPING  
Backstepping greatly reduces the chances for crack-  
ing of the share, and it also greatly reduces warping.  
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.  
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.  
After welding Cast Iron, protect the casting against  
fast cooling. Put it in a container of warm, dry sand or  
lime.  
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.)  
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.  
hot  
White brittle  
cast iron  
Cast Iron Plate Preparation  
cold  
cold  
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. This  
is especially important on thick castings where maxi-  
mum strength is required.  
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 other piece has no weld on it.  
(See drawing below.)  
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b-16  
b-16  
OPERATION  
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).  
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.  
Scrap steel back-up strip  
(b)  
(c)  
(a)  
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.  
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.  
Low Hydrogen Group (AWS E7018)  
(d)  
(e)  
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.  
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. MILDꢀSTEELꢀELECTRODESꢀmay 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.  
Motions  
E
D
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.  
START  
F
C
B
G
SIDE  
VIEW  
A
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C-1  
C-1  
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.  
• 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 (S20925) - 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.  
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D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
OIL: Check the oil level after every 5  
hours of operation or daily. BE SURE  
TO MAINTAIN THE OIL LEVEL.  
WARNING  
Change the oil the first time after 20 hours of opera-  
tion. Then, under normal operating conditions, change  
the oil after every 100 hours or once every 6 months  
whichever occurs first. If the engine is operated under  
heavy load or in high ambient temperatures, change  
the oil every 25 hours.  
• Have qualified personnel do all maintenance  
and troubleshooting work.  
• Turn the engine off before working inside the  
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  
the EXPLODED VIEW AND PARTS LIST at the  
back of this manual.  
FIGURE D.1 - OIL DRAIN AND REFILL  
LOCATION  
---------------------------------------------------------------------  
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.  
2
3
1
Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep your  
hands, hair, clothing, and tools away from the recoil  
housing, fans, and all other moving parts when start-  
ing, operating, or repairing this machine.  
1. OIL DRAIN PLUG  
2. OIL FILL PLUG  
3. OIL LEVEL  
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 first. 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.  
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D-2  
D-2  
MAINTENANCE  
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.  
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).  
ENGINE ADJUSTMENTS  
FIGURE D.2 - CLEAN AREA  
WARNING  
1
1
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  
Shop.  
1. FINGER GUARD AREA  
CAUTION  
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.  
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 AIRꢀCLEANER.  
FIGURE D.3 - CLEAN COOLING SYSTEM  
------------------------------------------------------------------------  
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.  
1
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.  
1. REMOVE DIRT AND DEBRIS FROM THIS  
LOWER AREA.  
CAUTION  
Periodically clean the muffler area to remove com-  
bustible debris.  
------------------------------------------------------------------------  
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D-3  
D-3  
MAINTENANCE  
SPARK PLUG SERVICE  
Spark Plug is located between muffler and Air  
Cleaner. See Figure D.4.  
TAbLE D.1  
ENGINE MAINTENANCE PARTS  
FIGURE D.4  
PART  
S
a
n
KOHLER PART #  
SPARK PLUG  
(RESISTOR)  
Champion RC 12YC  
(GAP .030” [.76mm])  
Kohler 17 083 03-S  
Kohler 17 083 08-S  
AIR FILTER ELEMENT  
AIR FILTER PRECLEANER  
Spark Plug  
Location  
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.  
CAUTION  
Replace or clean engine maintenance parts per the  
interval outlined in the engine owner’s manual.  
• be sure not to cross thread Spark Plug when  
reinstalling.  
OPERATIONAL CLEARANCE  
• This area is HOT if engine has been running.  
Allow engine to cool before servicing.  
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 restricted.  
------------------------------------------------------------------------  
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  
1
2
2
1
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.  
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D-4  
D-4  
MAINTENANCE  
RECEPTACLES: Keep the electrical receptacles in  
good condition. Remove any dirt, oil, or other debris  
from their surfaces and holes.  
GENERATOR/WELDER MAINTENANCE  
STORAGE: Store the BULLDOG™ 5500 in clean,  
dry, protected areas.  
CAbLE CONNECTIONS: Check the welding cable  
connections at the weld output terminals often. Be  
sure that the connections are always tight.  
CLEANING: Blow out the generator and controls  
periodically with low pressure air. Do this at least  
once a week in particularly dirty areas.  
NOTE: Lincoln offers a rotor removal kit for any ser-  
vice which requires removal of the rotor from the  
engine. See the ACCESSORIES section for further  
details.  
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.  
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.  
CAUTION  
Do not attempt to polish slip rings while engine  
is running.  
• 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.  
---------------------------------------------------------------------  
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 the brushes will  
seat onto the slip rings and replace bearing bracket  
end cover (Item 2).  
• With a jib hoist or crane, lift the unit upward and  
remove loose cradle from engine/generator  
assembly.  
FIGURE D.6. – bRUSH REMOVAL AND REPLACEMENT  
                    5
                                                                                                                                                                                                                                                                        6
                                                                                                                                                                                                                                                                                                                                    B
                                                                             S
                                                                                                                                                                                                                                               S
2
1
3
6
3
6
1
2
4
5
1. BRUSH, BRUSH HOLDER ASSEMBLY  
2. BEARING BRACKET END COVER  
3. STATOR END BRACKET  
4. (2) SCREWS  
5. (2) BRUSHES  
6. CABLE TIE  
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D-5  
D-5  
MAINTENANCE  
FIGURE D.7. - MAJOR COMPONENT LOCATIONS  
13  
                                                                                      2
10  
1
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   1
4
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     R
L
                                            8
                                                                         5
                                            9
9
1. CRADLE ASSEMBLY  
2. ROTOR, BLOWER, AND BEARING ASSEMBLY  
3. STATOR ASSEMBLY  
4. BRUSH, BRUSH HOLDER ASSEMBLY AND BEARING BRACKET END COVER  
5. REAR CONTROL PANEL  
6. TOLERANCE RING  
7. BAFFLE RING  
8
8. CONTROL PANEL ASSEMBLY  
9. ROOF ASSEMBLY  
10. SIDE PLATE  
5
11. MUFFLER AND ENGINE  
12. ENDGINE END BRACKET  
13. ENGINE END BRACKETS MACHINING  
1
12  
11  
2
7
3
13  
6
4
10  
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E-1  
E-1  
TROUbLESHOOTING  
HOW TO USE TROUbLESHOOTING GUIDE  
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.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
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.  
Step 1. LOCATE PROBLEMꢀ(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.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
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.  
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E-2  
E-2  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
PRObLEMS  
No generator power or welding output. 1. Disconnect anything plugged into  
auxiliary receptacles and weld loads.  
2. Open lead in flashing or field circuit.  
3. Open flashing diode (D1)  
4. Faulty brushes.  
5. Faulty rheostat (R1).  
6. Faulty field rectifier (D1).  
7. Faulty capacitor (C1).  
8. Faulty stator field winding.  
9. Faulty rotor.  
10. Dirty slip rings, clean slip rings when  
not in use.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
Generator power is available but unit 1. Loose connection to output stud.  
will not weld.  
2. Work not connected.  
3. Electrode holder loose.  
4. No open circuit voltage at output  
studs. Open lead in weld circuit.  
5. 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.  
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E-3  
E-3  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
PRObLEMS  
Unit will weld but low or no generator 1. Circuit breaker open.  
power is available.  
2. Loose or open connection with elec-  
trical plug-in component.  
3. Current control dial not at “140”.  
4. No open circuit voltage at receptacle.  
Open lead in receptacle circuit.  
5. No open circuit voltage at receptacle.  
Bad receptacle.  
6. 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.  
2. Engine requires service to head, car-  
buretor, filters, oil, spark plug and/or  
gas.  
Engine sputters but will not start.  
1. Bad gas, bad filter, air cleaner, spark  
plug, and/or breather.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
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.  
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E-4  
E-4  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
PRObLEMS  
1. Spark plug boot or wire off, loose or  
wet.  
Engine will not start.  
2. Fuel shutoff valve is closed.  
3. 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).  
4. Choke left in full choke position and  
carburetor flooded.  
5. Fuel line clogged or closed.  
6. Recoil start will not engage with  
engine.  
7. Fouled spark plug.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
8. Engine requires service to head,  
head gasket, and/or valves.  
9. Float open in carburetor & gas leak-  
ing from bowl.  
10. Engine operated with low oil level.  
Engine is seized and recoil start will  
not move.  
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.  
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F-1  
F-1  
DIAGRAMS  
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F-2  
F-2  
DIMENSION PRINT  
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NOTES  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
Spanish  
No toque las partes o los electrodos  
bajo carga con la piel o ropa moja-  
da.  
Mantenga el material combustible  
fuera del área de trabajo.  
Protéjase los ojos, los oídos y el  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
Aislese del trabajo y de la tierra.  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Isolez-vous du travail et de la terre.  
Gardez à l’écart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material!  
Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e electro-  
dos com a pele ou roupa molhada.  
Isole-se da peça e terra.  
Mantenha inflamáveis bem guarda-  
dos.  
Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE  
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE  
ESTE EQUIPOY 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-  
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS  
SIND EBENFALLS ZU BEACHTEN.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant l’entre-  
tien.  
N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öffnen;  
Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES  
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
• 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 WEBꢀSITE: www.lincolnelectric.com  
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