Lincoln Electric BIG RED IM10019 manual

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • BIG RED 600 ™ OPER A T OR’S MANU AL IM1 0 0 1 9 August, 2009 Safety Depends on You Lincoln arc welding and c[...]

FOR ENGINE pow ered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

ARC R A Y S can bur n. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b . Use suitable clothing made from durable flame-resistant material to protect your skin and tha[...]

FOR ELECTRIC ALL Y pow ered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electri[...]

iv SAFETY iv Mar. ‘93 PRÉC A UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. L[...]

v v Thank Y ou 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pa[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...........................[...]

Page Maintenance ....................................................................................................Section D Safety Precautions ................................................... .............................................D-1 Routine and Periodic Engine Maintenance ................................................ ...........D-1[...]

A-1 INS T ALLA TION BIG RED™ 600 A-1 TECHNIC AL SPECIFIC A TIONS - BIG RED™ 60 0 (K281 1-1) Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder Idle 1890 173 cu. in 12VDC battery Fuel F3L 912 44HP (33 kw) (2.83L) & Starter (20 US gal) Diesel Engine @ 1800 RPM Full Load 1800 75.7L Bore x Stroke Oil: 3.[...]

A-2 INS T ALLA TION BIG RED™ 600 A-2 SAFETY PRECAUTION Read this entire installation section before you start installation. LOCA TION AND VENTILA TION The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the eng[...]

A-3 INS T ALLA TION BIG RED™ 600 A-3 TOWING Use a recommended trailer for use with this equip- ment for road, in-plant and yard towing by a vehi- cle(1). If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard or dam- age the welding equipment. Some of the [...]

A-4 INS T ALLA TION BIG RED™ 600 A-4 ENGINE BREAK-IN Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we o ff er . W hi le i t is n or ma l to s e e a sm al l am ou nt o f crankcase oil consumption during initial operation, excessive oil use, wetstacking (oil or tar like sub- stance at the e[...]

A-5 INS T ALLA TION BIG RED™ 600 A-5 MUFFLER OUTLET PIPE Remove the plastic plug covering the muffler outlet tube. Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired position . SP ARK ARRESTOR Some federal, state or local laws may require that petrol or d[...]

A-6 INS T ALLA TION BIG RED™ 600 A-6 AUXILIAR Y POWER RECEPT ACLES The auxiliary power of the BIG RED™ 600 consists of Single Phase 60Hz Power. Out put Voltage is within +/- 10% at loads up to rated capacity. One 120VAC NEMA (5-20R) 20 amp duplex recepta- cle is protected by a 20 amp circuit breaker that pro- vides 2400 watts Peak / 2400 watts [...]

A-7 INS T ALLA TION BIG RED™ 600 A-7 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off Welder before making any electrical con- nections. ------------------------------------------------------------------------ The LN-15™ Across-the-Arc model, LN-25™ with or without an internal contactor, and LN-25™ PRO may be used with the BIG RED™ 60[...]

B-1 OPER A TION B-1 GENERAL DESCRIPTION The BIG RED™ 600 is a diesel engine driven welder, offering reliable DC arc welding performance, with outstanding arc characteristics for all welding applica- tions. The BIG RED™ 600 is both a rugged three cylinder, diesel engine driven 600 amp DC arc welder and 3.6 KW AC power generator. This powerful ge[...]

B-2 OPER A TION B-2 WELDING CONTROLS (Items 1-5) 1. OUTPUT RANGE SELECTOR SWITCH A 5 position switch that provides 5 overlapping out- put current settings: • 65 - 115 • 105 - 220 • 150 - 330 • 200 - 435 • 300 – Maximum Note: Do not switch while welding 2. OUTPUT CONTROL Pro vide s fine a djus tmen t of the c urre nt and o pen circuit vo[...]

B-3 OPER A TION B-3 5 . LOCAL / REMOTE CONTROL SWITCH and REMOTE RECEPTACLE The toggle switch provides the option of controlling the welding output at the control panel or remotely. For control at the control panel set the switch in the "LOCAL" position. For remote control set the switch in the "REMOTE" position. The receptacle [...]

B-4 OPER A TION B-4 17. 120 VAC DUPLEX RECEPTACLE Single-pole 20A rated. Provides overload protec- tion for the 120VAC (5-20R) NEMA Duplex Receptacle. 18. CIRCUIT BREAKERS Single pole 15A rated. Provides overload protection for the 120VAC European (IEC-309) receptacle. 19. 120 VAC RECEPTACLE European (IEC-309) receptacle rated up to 15 amps and is [...]

B-5 OPER A TION B-5 WELDER OPERA TION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example a 60% duty cycle, represents 6 minutes of load and 4 minutes of no load in a 10 minute period. ELECTRODE INFORMATION The BIG RED™ 600 is designed for horizontal, ver- tical up, and overhead welding wit[...]

B-6 OPER A TION B-6 TIG The BIG RED™ 600 can be used for Scratch-Start of DC TIG welding applications. Use the “Output Range Selector” and “Output Control Adjustments” to set the desired current. To initiate a weld, the tungsten electrode is then scratched on the work which establishes the arc. To stop the arc, simply lift the TIG torch a[...]

B-7 OPER A TION B-7 CONST ANT CURRENT OPER A TION WITH A LINCOLN ELECTRIC WIRE FEEDER Lincoln Electric does NOT recommend constant current semiautomatic welding for applications which need to meet specified weld metal chemical or mechanical property requirements or weld quality requirements. ---------------------------------------------------------[...]

B-8 OPER A TION B-8 BIG RED™ 600 AUXILIAR Y POWER: The auxiliary power is independent of the welding power and thus not effected by the weld control set- tings. Simultaneous Welding and Auxiliary Power Loads The auxiliary power ratings are with no welding load. Simultaneous welding and power loads are speci- fied in the following Table B.4. Weld [...]

C-1 A CCESSORIES C-1 BIG RED™ 600 OPTIONAL FEA TURES K2641-2 FOUR WHEELED STEERABLE YARD TRAILER For in plant and yard towing. Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination Hitch. K2636-1 TRAILER - Two-wheeled trailer with optional fender and light package. For highway use, consult applicable federal, state, and loca[...]

D-1 MAINTENANCE D-1 BIG RED™ 600 SAFETY PREC A UTIONS Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal i[...]

D-2 MAINTENANCE D-2 3. R emove loos e dirt from ele ment with co mpressed air or water hose directed from inside out. Compressed Air: 100 psi maximum with nozzles at least one inch away from element. Water Hose: 40 psi maximum without nozzle. 4. Soak element in a mild detergent solution for 15 minutes. Do not soak more than 24 hours. Swish element [...]

D-3 MAINTENANCE D-3 FUEL FIL TERS When working on the fuel system • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The BIG RED™ 600 is equipped with a Fuel Pre- Filter/Water Separator Assembly located before the lift pump and a Secondary Fuel Filter located[...]

D-4 MAINTENANCE D-4 5. Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard. If you do not hear the click you have not rotated the ring far enough and the ele- ment is not in the locked position. Another indica- tion that the ring is in the locked position is that one set (it doesn’t [...]

D-5 MAINTENANCE D-5 PREVENTING BA TTER Y BUCKLING Tighten nuts on battery clamp until snug. CHARGING THE BA TTER Y When you charge, jump, replace, or otherwise connect bat- tery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The Vantage positive (+) battery terminal has a red terminal cove[...]

D-6 MAINTENANCE D-6 WELDER / GENERA TOR MAINTENANCE STORAGE Store the BIG RED™ 600 in clean, dry protected areas. CLEANING Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOV AL AND REPLACEMENT It is normal for the brushes and slip rings to wear and dark- en[...]

E-1 TR OUBLESHOO TING E-1 BIG RED™ 600 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. C A UTION This Troubleshooting Guide is provided to help you locate and repa[...]

E-2 TR OUBLESHOO TING E-2 BIG RED™ 600 Observe all Safety Guidelines detailed throughout this manual 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. C A UTION PROB[...]

E-3 TR OUBLESHOO TING E-3 BIG RED™ 600 Observe all Safety Guidelines detailed throughout this manual 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. C A UTION PROB[...]

F-1 DIA GRAMS F-1 BIG RED™ 600 A M22253 ELECTR IC SHO CK CAN KI LL WA RN ING Do no t o pe rate wi th c o v e r s rem ov ed Di sc on nec t i np ut power be for e se r v i c i ng Do no t t ouch electrica lly li ve pa rts Only quali fi ed per sons sho uld ins tall, use or s e r v i c e thi s e qu ipm ent 1. TU RN O F F TH E E NG I N E A N D DI S CO [...]

F-2 DIA GRAMS F-2 BIG RED™ 600 M2 2 2 5 3 A 4. LOC AT E L EAD S 3D & 6J . (S EE F IG U R E 2 ) . C UT B O T H L E A D S AS S HO W N. 5. S T R I P ALL F OU R LEA D S 13 M M ( . 50 in. ) 6 . C ON NE CT L E A DS FRO M CI RC UIT B R EA K ER & R EC EP T AC E T O RC D A S S H O W N & T I G H T E N LEA D S T O 2. 4N M (21 in-l b). (SEE F IG [...]

F-3 DIA GRAMS F-3 BIG RED™ 600 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code num[...]

F-4 DIA GRAMS F-4 BIG RED™ 600 M 22 2 23 A 65.10 1653.7 27.00 685.8 10.01 254.3 6.29 159.8 1.28 32.5 23.32 592.2 31.70 805.2 45.15 1146.7 59.50 1511.3 N.A. CEN TER O F GRAVITY W ITH OIL IN E NGINE AND EMPT Y FUEL TANK. 32.25 819.2 17.50 444.5 N.A. 28.82 732 30.00 762 36.87 936.6 39.84 1011.8 NOTE: This diagram is for reference only. It may not be[...]

NO TES BIG RED™ 600[...]

W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INS TR UCTION FOR THIS EQUIPMENT AND THE CONSUMABLES T O BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F ABRIC [...]

W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INSTR UÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E AS P AR TES DE USO , E SIGA A S PRÁTIC A S DE SEGUR ANÇA DO EMPREG ADOR. • Kee p your h ead ou t of fum es. • Use v enti lati on or ex h[...]

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]