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Lincoln Electric IM10019 User's Manual

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1. asez 8 aawooze 102 9002 NOILISOd HOLLS HOLO NINMOHS GION310S HOLIMS NMOGLNHS M OIL HOILS OL 1S3HV3N 415 OL Q3193NNOO 5 3ALLISOd a9 vs q D 8E02 1NOHJ NO GALS 1945 5 w o asoz DC a 4 NO 901 aNnouo M Loz V902 TANVd 1 YOLVLS NO 5 WHLN3N HN 0020 79134 NOILLO3NNOO HOLIMS HO123 13S vs SWYM vaviev V AlaWassv wo jew FOND SS Vd AD WOTAN ama 1 3SvHd en on 140 n H313AL 10A SSNIONIM HOLVLS 257 HOLVIS 140 NOLLO3NNOO HOLIMS 0103738 339 7 INVHOVIG L LL8ZH 009 919 BIG RED 600 LINCOLN E
2. ub al gllg og pull canis LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
3. terminal of the welder 3 Set the CV CC mode of the wire feeder to CC Refer to wire feeder operator manual for details on setting the wire feeder in the CC mode and for set ting welding parameters 4 Attach the single lead from the front of the wire feeder to work using the spring clip at the end of the lead This is a sense lead to supply current to the wire feeder motor it does not carry welding current 5 When the gun trigger is closed the current sensing circuit will cause the wire to begin to feed and the welding process is started NOTE The LN 25 K444 1 Remote Control Module K431 and Remote Cable K432 can not be used with the BIG RED 600 See the appropriate connection diagram in Section F WARNING If you are using an LN 25 without an internal contactor the electrode will be energized when the BIG RED 600 is started The Wire Feeder sensor has full OCV potential between spring clip and work return Turn machine off when attaching spring clip 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 FIGURE A 1 Electrode BIG RED 600 LN 15 ACROSS THE ARC LN 25 LN 25 PRO BIG RED 600 LINCOLN B OPERATION B 1 SAFETY INSTRUCTIONS Read and understand this entire section before operating
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5. 9 CIRCUIT BREAKER 6 The battery circuit breaker protects the engine cir cuitry that powers the three gauges fuel hours temperature and pressure It also protects the engine shutdown relay timer delay relay hot start relay hold solenoid and flashing circuitry When the circuit breaker opens because of a fault the engine will crank but will not start 10 OIL TEMPERATURE GAUGE An indicator of engine oil temperature 11 OIL PRESSURE GAUGE SA An indicator of engine oil pressure 12 ENGINE PROTECTION A warning indicator light for high oil temperature or low oil pressure The light remains off with proper oil temperature and proper oil pressure If a fault is detected the light will turn on and the engine pro tection system will stop the engine The light will remain on when the engine has been shut down In order to try and re start the engine the engine protection system must be reset by returning the RUN STOP switch to the STOP position Note The light remains off when the RUN STOP switch is in the RUN position prior to starting the engine However if the engine is not started within 60 seconds the light will come on When this hap pens the RUN STOP switch must be returned to the STOP position to reset the engine protection System and light 13 BATTERY CHARGING LIGHT An indicator light for low no battery charging The light is off when the battery charging system is functioning normally If light turns on t
6. e solieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas electro dos com a pele ou roupa molhada sole se da pe a e terra 888 9508888 080865 98 97 5 ATUSHELT Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e 00 L CIE IR EA Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo l e i 9 8 io e QRERR HERHSEGSRHR XD st B Oo eUa AIX MIS ei HY 50 4851 58 8 SE au su ya ENY AAS LD Gl oa y e oft ALUN 3 ais dune le cl jai pull 292271 lali AU aal JUS thes READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
7. Do not operate with doors open or guards off WM Stop engine before servicing Keep away from moving parts See additional warning information throughout this operator s manual and the Engine manual as well ROUTINE AND PERIODIC MAINTENANCE DAILY Check the crankcase oil level Refill the fuel tank to minimize moisture condensa tion in the tank Open the water drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds Repeat the above drainage procedure until diesel fuel is detected in the co WEEKLY Blow out the machine with low pressure air periodical ly In particularly dirty locations this may be required once a week ENGINE MAINTENANCE Refer to the Periodic Checks section of the Engine Operator s Manual for the recommended maintenance schedule of the following a Engine Oil and Filter b Air Cleaner C Fuel Filter and Delivery System d Cooling Blower Belt Battery f Cooling System Refer to Table D 1 at the end of this section for vari ous engine maintenance components ENGINE OIL CHANGE gt Drain the engine oil while the engine is warm to assure rapid and complete draining It 15 recommend ed that each time the oil is changed the oil filter be changed as well Be sure the unit is off Disconnect the negative bat tery cable to ensure safety Locate oil drain ho
8. KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment ANA 4 j 1 8 Turn the engine off before troubleshooting and maintenance 3 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 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated ELECTRIC AND SR MAGNETIC FIELDS SN may be dangerous
9. As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always
10. OIL A The BIG RED 600 is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or better Check the oil level before starting the engine If it is not up to the full mark on the dip Stick add oil as required Check the oil level every four hours of running time during the first 35 running hours Refer to the engine Operator s Manual for spe cific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the engine Operator s Manual for the proper service and maintenance intervals The machine is equipped with FUEL an oil drain valve USE DIESEL FUEL ONLY A WARNING Fill the fuel tank with clean fresh fuel The capacity of the tank is 20 gals 75 7 ltrs When the fuel gauge reads empty the tank contains approximately 2 gals 7 6ltrs of reserve fuel A WARNING NOTE A fuel shut off valve is located on the pre filter sediment filter Which should be in the closed position when the welder is not used for extended periods of time BIG RED 600 LINCOLN INSTALLATION A 4 ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil consumption during initial operation excessive oil use wetstacking oil or tar like sub stance at the exhaust port or excessiv
11. seated Note The element will only go on one way Never use excessive force when mounting the element to the header BIG RED 600 LINCOLN wit 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 matter which one of arrows located on the outside of the ring should be located directly under the air vent valve 6 Open the fuel shutoff valve lever in line with the hose 7 Open the air vent valve on the front of the filter header until fuel emerges free of air bubbles and then close the air vent valve Note Consult your engine operation manual for information on air bleeding the entire fuel system SECONDARY FUEL FILTER The Secondary Fuel Filter is a spin on cartridge type mount directly to the engine Consult your engine operation manual for complete information on service intervals and element changing procedures COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically Consult the engine owners manual for the proper frequency and proce dure COOLING BLOWER BELT The following procedure should be followed to replace the cooling blower belt 1 Allow the machine to cool
12. 2 Unfasten and slide the battery holder out from the welder Disconnect the negative battery cable Remove engine case side Loosen air cleaner hose clamp and detach hose Remove screws securing the engine end panel with air box and air cleaner attached to the base and roof Pull this assembly away from roof and base This will provide access for removing the belt from the blower pulley in step 8 7 Loosen the alternator mounting bolts and rotate the alternator towards the engine 8 Remove the old cooling blower belt and install a new one 9 Adjust the cold belt tension to 63 73 lbs midway between any two pulleys 10 Reinstall the air cleaner hose engine case side and end panel Reattach the negative battery cable Slide in and refasten the battery holder 11 Check the cooling blower belt tension after 100 hours of operation Follow steps 1 2 3 4 9 amp 10 Ook BATTERY HANDLING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY discon nect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove battery from welder by discon Ww necting negative cable first then posi tive cable and battery clamp When rein stalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then c
13. ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 50 84 4507 2 8 e sis SR e OER E 5 Ff 59 2475 e 522 15 55 87 R Ash 712724714 27 amp HSHM las ul jan 2 j A ox ui A Sall Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier serv
14. F 5 C Do not use kerosene See the Engine Operator s Manual for instructions on replacing the fuel filter BLEEDING THE FUEL SYSTEM You may need to bleed air from the fuel system if the fuel filter or fuel lines have been detached the fuel tank has been ran empty or after periods of long stor age It is recommended that the fuel shutoff valve be closed during periods of non use A WARNING To avoid personal injury do not bleed a hot engine This could cause fuel to spill onto a hot exhaust manifold creating a danger of fire BIG RED 600 LINCOLN 5 wi MAINTENANCE D 3 FUEL FILTERS WARNING 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 after the lift pump and before the fuel injectors The Fuel Pre Filter Water Separator is mounted to the engine block just below the lift pump The Secondary Fuel Filter is mounted directly to the engine just above the oil filter FUEL PRE FILTER WATER SEPARATOR ASSEMBLY The pre filter is a 150 micron screen designed to pro tect against gross fuel contamination of the water sep arator element and the Secondary Fuel Filter If the pre filter becomes plugged it may be removed inspected cleaned and reinstalled In general this only needs to be done with each water separator el
15. be switch off and turned back on Defective CR3 Replace CR3 Fuel Filters dirty clogged gelled Colder Climates for gelled fuel remove and replace filters Run diesel fuel treatment that dis solves the wax crystals until full power has been revolved Main filter element and or Inline Fuel Filter may need to be replaced High oil temperature or low oil pressure engine protection light lit Low oil pressure engine protec tion light lit Check oil level Consult engine service dealer High oil temperature engine protection light lit Faulty oil pressure switch Faulty oil temperature switch Contact authorized local Engine Service Shop Low output of battery charging alternator battery charging light lit 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 BIG RED 600 LINCOLN 8 E 3 TROUBLESHOOTING ET Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION load Engine runs rough Dirty fuel or air filters may need cleaned replaced Water in fuel Fuel injector clogged or malfunc tioning Engine will not shut off Fuel Shutdown solenoid not func tioning properly linkage binding Battery does not stay cha
16. is independent of the welding power and thus not effected by the weld control settings Full power is available provided welding output is below 200 amps Above 200 amps refer to the Simultaneous Welding and Auxiliary Power chart in the operation section of this manual BIG RED 600 LINCOLN B 2 OPERATION B 2 CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel Refer to Figure B 1 and the explanations that follow Figure B 1 Case Front Panel Controls LINE 8 WELDING CONTROLS Items 1 5 2 OUTPUT CONTROL 1 OUTPUT RANGE SELECTOR SWITCH Provides fine adjustment of the current and open 0 circuit voltage from minimum to maximum within A 5 position switch that provides 5 overlapping out each Range put current settings 1 is minimum and 10 is maximum 65 115 105 220 3 WELD MODE SELECTOR SWITCH 150 330 Provides selection of either Stick Arc Gouging Mode or TIG Mode 200 435 4 VOLT AMP METERS optional Optional analog volt and amp meter kit available for Note Do not switch while welding easy installation into front panel See Accessory Section For K number BIG RED 600 LINCOLN ET OPERATION ii 5 L
17. plastic cap Make sure its flange rests on the O ring 9 Screw on the cap ring and tighten hand tight 10 Remember to open the fuel shutoff valve Lever in line with the hose before starting the engine WATER SEPARATOR ELEMENT The water separator element is a two stage filter with a special filtration water separating media and an expanded water reservoir providing maximum protec tion against water in the fuel The recommended change interval for the water separator element is 1 000 hours The procedure for changing the element is as follows 1 Close the fuel shutoff valve Lever should be per pendicular to the hose located on the side of the Fuel Pre Filter Water Separator Assembly 2 Rotate the quick change ring located just below fil ter header clockwise approximately 1 2 turn and slide it down and off of the element 3 Grasp the element and pull down with a slight rock ing motion to remove the element from the grom met post on the bottom of the filter header 4 Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header Now rotate the element may take almost 1 full turn with a slight upward pressure until the element begins to further engage the header With the proper orienta tion now established apply additional pressure to seat the element in the filter header You should feel the element pop into place when properly
18. 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 WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page Section A Technical Specifications 5 2 Idee eei A 1 Sately PrecduliofiS o 2 LOCA
19. the 150 330 position and the Output Current Adjustment set ting to get 175 amps Some arc instability may be experienced with EXX10 electrodes when trying to operate with long arc techniques at settings at the lower end of the open circuit voltage range CAUTION DO NOT attempt to set the Current Range Selector between the five points designated on the nameplate ARC GOUGING Using the Output Range Selector and Output Control Adjustment set the output to the desired level for the gouging electrode being used see table B 2 TABLE B 2 Carbon Diameter Current Range DC elec trode positive 1 8 3 2mm 60 90 Amps 5 32 4 0mm 90 150 Amps 3 16 9 4 8mm 200 250 Amps 1 4 6 4mm 300 400 Amps 5 16 8 0mm 350 450 Amps 3 8 9 5mm 450 600 Amps BIG RED 600 LINCOLN 0 OPERATION 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 away from the work piece The tungsten may then be scratched on the work piece to restrike the arc If a high frequency start is desired the K930 2 TIG Module can be used with the BIG RED 600 The BIG RED 600 and any high frequency gener
20. the MAINTENANCE section for detailed information on testing and reset ting it A GFCI module should be properly tested at least once every month The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle INSTALLATION A 6 RESIDUAL CURRENT DEVICE READY The BIG RED 600 is configured to allow for the addition of a Residual Current Device RCD to pro tect the 240V Single Phase Receptacle The auxiliary power area on the front panel of the BIG RED 600 has a hole sized and shaped to accept a typical 2 pole RCD along with a protective rubber boot A cover plate with a label RCD READY covers the hole and secures a mounting bracket on the backside of the panel Note The RCD should be rated for at least 15 amps There are many suppliers of RCD s One example is Allen Bradley part number 1492 RCD2A40 The protective boot can be obtained from APM Hexseal part number HE 1035 See Section Diagrams of this Operator s Manual for instructions on installing an RCD and protective rub ber boot STANDBY POWER CONNECTIONS The BIG RED 600 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The BIG RED 600 can be permanently
21. work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K2861 1 REMOTE CONTROL 100 ft 30 4m Portable control provides same dial range as the out put control on the welder Has a convenient twist lock plug for easy connection to the welder K2863 1 METER KIT Easy to read analog meters for volts and amps Easy to install K2864 1 SPARK ARRESTOR Includes a heavy gage steel approved spark arrestor attaches to the muffler exhaust tube Includes clamp BIG RED 600 LINCOLN 5 D 1 SAFETY PRECAUTIONS A WARNING 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 is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure
22. 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 5 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode a
23. 4 DIAGRAMS F 4 epoo 5 e 104 23931419S si ay 5 euo poised si epoo siy Aq je 10 eje4n99e jou juo 104 51 SIUL 66060 1 NI ALIAVHO 1 BIG RED 600 LINCOLN E NOTES BIG RED 600 LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung
24. 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufac
25. AMP for 240 VAC European IEC 309 PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 2 i i 36 87 in 28 28 in 65 1 in 1657 lbs 752 kg 916 5 mm 718 3 mm 1653 5 mm 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 To Top of enclosure add 8 28 210 1mm to top of exhaust pipe BIG RED 600 LINCOLN A 2 SAFETY PRECAUTION Read this entire installation section before you start installation A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 9 X D MOVING PARTS injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual LOCATION AND VENTILATION 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 engine exhaust fumes are properly vented to an outside area STORING 1 Store the machine in a cool dry pl
26. AND Covered terminals that provide welding connection points for the electrode and work cables GROUND STUD Protects both 120VAC Auxiliary Power recepta cles ENGINE OPERATION STARTING THE ENGINE 1 Open the engine compartment door and check that the fuel shut off valve located screwed into the fuel filter housing is in the open position lever to be in line with the hose Check for proper oil level Close engine compart ment door Remove all plugs connected to the AC power receptacles Set the RUN STOP switch to RUN Observe that the battery charging light is on and fuel is in the fuel tank see fuel gauge Within 30 seconds press and hold the engine START button until the engine starts Release the engine START button when the engine starts Check that the engine protection and battery charging lights are off The engine protection light is on after starting the engine will shutdown in a few seconds Investigate any indicated problem OPERATION B 4 8 Allow the engine to warm up for several minutes before applying a load Allow a longer warm up time in cold weather COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 15 C 5 F If the engine must be frequent ly started below 15 C 5 F it may be desirable to install additional starting aids The use of No 1D diesel fuel is r
27. BIG RED 600 For use with machines having Code Numbers 9 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 OPERATOR S MANUAL 1809001 E fr EE ia BS esit a Inc NCOLN Copyright Lincoln Global Inc e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com ABS Quality Eval to ISO 9001 Re CERTIFICATE NUMBER 30273 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH
28. INTENANCE 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 REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and dark en slightly Inspect the brushes when a generator overhaul is necessary A WARNING Do not attempt to polish slip rings while the engine is running GFCI MODULE TESTING AND RESETTING PROCEDURE The GFCI module should be properly tested at least once every month or whenever it is tripped To proper ly test and reset the GFCI module If the module has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI mod ule This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the Duplex receptacle and turn the product ON Push the Test button located on the GFCI module The night light or other product should go OFF Push the Reset button again The light or othe
29. K ARRESTER If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable DO NOT OPERATE ENGINE WHILE INSTALLING before you attach the charger leads After the battery is THE SPARK ARRESTER charged reconnect the positive battery cable first and the negative cable last Failure to do so can result in damage to the internal charger components NAMEPLATES WARNING DECALS MAINTE NANCE Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number Follow the instructions of the battery charger manufacturer for proper charger settings and charging time Table D 1 Engine Maintenance Components make PARTNUMBER SERVICEINTERVAL CLEAN AS NEEDED Air Cleaner Element DONALDSON P822768 REPLACE EVERY 200 HOURS Cooling Blower Belt DEUTZ 223 5256 GATES 7580 Oil Filter Element DEUTZ 117 4418 PUROLATOR PER2168 NAPA 1820 FRAM PH3776 MAINTENANCE Fuel Filter Element DEUTZ 117 4423 PUROLATOR PC42 NAPA 3358 DECAL FRAM P4102 Water Separator LINCOLN M16890 C REPLACE EVERY Element STANADYNE 31572 1000 HOURS Fuel Pre Filter LINCOLN M16890 B INSPECT EVERY Screen STANADYNE 29575 1000 HOURS BCI INSPECT EVERY Battery Group 500 HOURS 34 BIG RED 600 LINCOLN 8 D 6 MAINTENANCE WELDER GENERATOR MA
30. OCAL 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 is for attaching an optional remote control equipment See Accessory Section For K number ENGINE CONTROLS Items 6 Through to 13 6 ENGINE HOUR METER FUEL GAUGE Combination hour meter fuel level gauge The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance The fuel gauge displays the level of diesel fuel in the fuel tank The operator must watch the fuel level closely to pre vent running out of fuel and possibly having to bleed the system RUN 2 STOP Q SWITCH The RUN position energizes the hold coil of the fuel solenoid hour meter and rotor flashing circuit The STOP position stops the engine Note Do not leave switch in RUN position when the engine is not running In the RUN position the battery will be discharged 8 START PUSH BUTTON Energizes the starter motor to crank the engine With the RUN STOP switch in the RUN position push and hold the Start button to crank the engine release as the engine starts Do not press while engine is running as this can cause damage to the ring gear and or starter motor
31. TION VEMUlAtlOM 5 0 2 e A 2 dE Au NE Eu M IINE IM A 2 Angle of Operation iii A 2 no MEL A 2 High Altitude Le tert enemas A 2 High temperature Operation sise A 2 NI A 3 i es meom A 3 Pre Operation Engine Service see A 3 jo M M A 3 RUG A 3 Engine c C A 4 Engine COOMA e Tm A 4 Battery Connection sise A 4 Pipe A 5 0 A 5 Welding Output Cables a baste aper re adap A 5 Auxiliary Power Receptacles Residual Device Ready Standby Power Connections A 6 Connection of Lincoln Electric Wire Feeders 4 22 22 000 A 7 e Safety IMSUCUCTIONS PE General Description Recommended 05 B 1 Controls 2 lugere m 2 Engine Controls B 3 UN AR ceeds c ue B 3 Engine Operation B 4 Starting the n B 4 Cold Weather Starting and Operation B 4 Stoping the B 4 We
32. ace when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from con struction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to cir culate oil to all the parts See the MAINTE NANCE section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place STACKING BIG RED 600 machines cannot be stacked INSTALLATION ANGLE OF OPERATION To achieve optimum engine performance the BIG RED 600 should be run in a level position The maximum angle of operation for the Deutz engine is 30 degrees fore and aft 40 degrees right and 45 degrees left If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the amount specified LIFTING The BIG RED 600 weighs approximately 1772165 804kg with a full tank of fuel 16571bs 752kg less fuel A lift bail is mounted to the machine and should always be used when lifting the machine WARNING Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lift ing Do not lift this machine using lift bail if i
33. articuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 dcus PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER s TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conforme
34. ating equipment must be properly grounded See the K930 2 TIG Module operating manuals for com plete instructions on installation operation and maintenance When using the TIG Module the OUTPUT control on the BIG RED 600 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module TABLE B 3 TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES 2 Tungsten Electrode DCEN DCEP Approximate Argon Gas Flow TIG TORCH Diameter in mm Flow Rate C F H min Nozzle Size 4 5 1 2 Thoriated 1 2 Thoriated Aluminum Tungsten Tungsten 3 3 8 2 15 5 20 15 80 4 5 6 70 150 5 5 6 150 250 E 6 7 8 250 400 400 500 6 8 8 10 500 750 750 1000 1 When used with argon gas The current ranges shown must be reduced when using argon helium pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 8 mm 6 3 8 in 10 mm 7 7 16 in 11 mm 8 _ in 12 5 mm 10 5 8 in 16 mm 5 TIG torch nozzles a
35. can be dangerous 5 8 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated 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 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 limits 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 Shielding gases used fo
36. e or service this equipment C ILL 1 TURN OFF THE ENGINE AND DISCONNECT THE NEGATIVE BATTERY CABLE 2 REMOVE THE SCREWS THAT SECURE THE LOWER CONTROL PANEL AND OPEN THE PANEL 3 WHILE HOLDING THE RCD MOUNTING BRACKET REMOVE THE TWO SCREWS SECURING THE COVER PLATE AND RCD MOUNTING BRACKET SET THE RCD MOUNTING BRACKET AND SCREWS ASIDE AND DISCARD COVERPLATE SEE FIGURE 1 LOWER CONTROL PANEL RCD MOUNTING BRACKET FIGURE 1 M22253 BIG RED 600 LINCOLN 2 DIAGRAMS F 2 4 LOCATELEADS 3D amp 6J SEE FIGURE 2 CUT BOTHLEADS AS SHOWN 5 STRIP ALL FOUR LEADS 13MM 50 in FIGURE 2 RCD OPENING CONNECT LEADS FROM CIRCUIT BREAKER amp RECEPT ACE TO RCD AS SHOWN amp TIGHTEN LEADS TO 2 4NM 21 in Ib SEEFIGURE 3 NOTE LEAD CONFIGURATION COAT AREA WHERE LEADS CONNECT TO RCD WITH A SILICONE RUBBER RTV SEALANT MOUNT RCD amp PROTECTIVE BOOT TO PANEL USING MOUNTING BRACKET amp SCREWS SET ASIDE IN STEP 3 240V PROTECTIVE RECEPTACLE CIRCUIT BREAKER REAR VIEW FRONT VIEW FIGURE 3 8 SECURE LOWER CONTROL PANEL IN PLACE 9 RECONNECT NEGATIVE BATTERY CABLE THE UNIT IS NOW READY FOR OPERATION M22253 BIG RED 600 LINCOLN DIAGRAMS FS F 3 Jequinu epoo jueuidinbo e 10 23931419S M si oui sjeued euo uo
37. e service classi fications SAE 10W30 is recommended for general all tempera ture use 5F to 104F 15C to 40C See engine owner s manual for more specific informa tion on oil viscosity recommendations OIL FILTER CHANGE Drain the oil Remove the oil filter with an oil filter wrench and drain the oil into a suitable container Discard the used filter Note Care should be taken during filter removal to not disrupt or damage in any way the fuel lines Clean the filter mounting base and coat the gasket of the new filter with clean engine oil Screw the new filter on by hand until the gasket con tacts the mounting base Using an oil filter wrench tighten the filter an additional 1 2 to 7 8 of a turn Refill the crankcase with the specified amount of the recommended engine oil Reinstall the oil filler cap and tighten securely Start the engine and check for oil filter leaks Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR FILTER A CAUTION EXCESSIVE AIR FILTER RESTRICTION WILL RESULT IN REDUCED ENGINE LIFE The air filter element is a dry cartridge type It can be cleaned and reused however damaged elements should not be reused Stop engine after 100 hours of running time and clean filter element replace the filter if necessary Service air cleaner regularly according to Engine Operator s Manual 1 Locate the air filter canister located be
38. e smoke is not normal Larger machines with a capacity of 350 amperes and higher which are operated at low or no load condi tions for extended periods of time are especially sus ceptible to the conditions described above To accomplish successful engine break in most diesel powered equipment needs only to be run at a reason ably heavy load within the rating of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suit able resistive load bank Note that any attempt to short the output studs by con necting the welding leads together direct shorting of the output studs or connecting the output leads to a length of steel will result in catastrophic damage to the gener ator and voids the warranty 2 Set the welder controls for an output cur rent and voltage within the welder rating and duty cycle Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level ENGINE COOLING SYSTEM The Deutz engine is air cooled by a belt driven axial blower The oil cooler and engine cooling fins should be bl
39. ecommended in place of No 2D at temperatures below 5 C 23 F STOPPING THE ENGINE Switch the RUN STOP switch to STOP This turns off the voltage supplied to the shutdown sole noid A backup shutdown can be accomplished by shutting off the fuel valve located on the fuel line Note Also put Run Stop switch in Stop position when engine is not running battery will be discharged otherwise TABLE B 1 TYPICAL BIG RED 600 FUEL CONSUMPTION Deutz F3L912 Engine Running Time for 44HP 33Kw 1800 RPM 75 7 L 20 Gal 2 6 liters hr 1890 R P M 69 gal hr 28 9 hrs DC CC Weld Output 7 5 liters hr 10 1 hrs 500A 40V 100 1 97 gal hr DC CC Weld Output 4 4 liters hr 600A 30V 40 1 16 gal hr Auxiliary Power 3 0 liters hr NOTE This data is for reference only Fuel consump tion is approximate and can be influenced by many factors including engine maintenance environmental conditions and fuel quality BIG RED 600 LINCOLN E OPERATION B WELDER OPERATION 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 with all types of DC stick electrodes For any electrode the procedures should be kept within the rating of the machine For information
40. effectively ground ed The National Electric Code lists a number of alter nate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder BIG RED 600 LINCOLN 8 A 6 AUXILIARY POWER RECEPTACLES 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 Continuous power Maximum current is 20 amps total One 120VAC European IEC 309 16 amp receptacle is protected by a 15 amp circuit breaker that provides 1800 watts Peak 1800 watts Continuous power Maximum current is 15 amps One 240VAC European IEC 309 16 amp receptacle is protected by a 15 amp 2 pole circuit breaker that provides 3600 watts Peak 3600 watts Continuous power The 2 pole circuit breaker disconnects both hot leads at the same time Maximum current is 15 amps 120 V RECEPTACLES A GFCI module protects the two 120V Auxiliary Power receptacles A GFCI Ground Fault Circuit Interrupter electrical receptacle is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault If this situation should occur the GFCI module will trip removing voltage from the output of the receptacle If a GFCI module is tripped see
41. ement change about every 1 000 hrs However if at any time excessive fuel contamination is suspected or a sudden fall off in engine performance is detected the pre filter screen should be inspected and cleaned Follow the following procedure 1 Close the fuel shutoff valve Lever should be per pendicular to the hose located on the side of the Fuel Pre Filter Water Separator Assembly 2 Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O ring 3 Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header Use a small screw driver or simi lar device to lift the plug part way out of the cavity to assist with its removal Be careful not to damage the pre filter screen with the tool used to remove the plug 4 Using a pair of pliers gently tug on the pull tabs of the pre filter screen in an alternating pattern to gradually remove the pre filter screen 5 Brush off any debris and rinse in diesel fuel 6 Re install the pre filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up Putting your fingers on the pull tabs push down evenly until the lower body of the pre filter screen contacts the floor of the upper cav ity 7 Re insert the large white volume plug into the upper cavity 8 Place the O ring onto the angled seal surface of the filter header and re install the
42. er to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operat ed environmental conditions like maintenance 5 Conformance with federal state and local laws 1 Consult applicable federal state and local laws regarding spe cific requirements for use on public highways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacture s instructions PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Stop engine while fueling 6 f Do smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel and allow fumes to clear before starting engine Do not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY DIESEL FUEL can cause fire
43. es porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est p
44. for lights power tools etc The BIG RED 600 delivers ideal DC arc characteris tic for each welding process Stick electrode welding Scratch Start TIG or carbon arc gouging to make the BIG RED 600 the ideal all purpose engine driven welder for on site work The BIG RED 600 has no PC Boards and no electronics The BIG RED 600 is service friendly with a minimal number of major parts simplifying in field servicing of the BIG RED 600 The generator is a dual stator and rotor design with two sealed bearings for mainte nance free service The rotors are copper wound design with two slip rings and brushes The stators are wound entirely with heavy gauge copper wire and insulated with NEMA class F insulation material The stator is then impregnated with three layers of high quality varnish After the stator is assembled using tie bars the entire assembly Is covered with an environ mentally protective coating These measures insure trouble free operation in the harshest environments RECOMMENDED APPLICATIONS WELDER The BIG RED 600 provides constant current DC welding output for stick SMAW and TIG GTAW welding scratch start In addition the Big Red can be used for Arc Gouging with carbons up to 9 5 mm 3 8 diameter The BIG RED 600 is not recommended for pipe thawing GENERATOR The BIG RED 600 provides smooth output for auxiliary power and emergency standby power The auxiliary power
45. g and Resetting Procedure D 6 Troubleshooting ss Section E Safety 30001100 E 1 How to Use Troubleshooting Guide E 1 Troubleshooting 2 E 3 DIAQrAMS Section F Instructions for Installing a Residual Current Device ssssssssenseeserneeeeeeee F 1 F 2 WARING DIAG F 3 DIM NSION PEE 4 Bc P 619 SERIES A INSTALLATION Al TECHNICAL SPECIFICATIONS BIG RED 600 K2811 1 INPUT DIESEL ENGINE System Deutz 3 cylinder Idle 1890 173 cu in 12VDC battery F3L 912 44HP 33 kw 2 83L amp Starter Diesel Engine 1800 RPM Full Load 1800 Bore x Stroke 3 94 x 4 72 100mm x 120mm RATED OUTPUT 104 F 40 C WELDER Welding Process Welding Output Output Range Max Weld OCV 500A 40V 100 600A 30V 4096 TIG 250A 20V 100 65A TO 250A 75 Volts RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power Single Phase 60 Hz AC OUTLETS VOLTS ____ 5 ___ POWER 1 20 120 2400 Watts 1 120 1800 Watts 1 3600 Watts ERS E R OTHER CIRCUIT BREAKERS 1 120VAC Duplex NEMA 5 20R GFCI protected 1 20 AMP for 120 VAC Duplex NEMA 1 120VAC European IEC 309 GFCI protected 1 15 AMP for 120 VAC European IEC 309 20AMP for Battery Charging Circuit 1 240VAC European IEC 309 1 15
46. he alterna tor or the voltage regulator may not be operating correctly or the cooling blower belt may be broken The light will remain on when the engine is stopped and the RUN STOP switch is in the RUN position AUXILIARY POWER 14 22 14 CIRCUIT BREAKER 2 pole 15A rated Provides overload protection for the 240VAC European IEC 309 receptacle 15 240 VAC RECEPTACLE European IEC 309 receptacle rated up to 15 amps and is IP44 rated Note A space is provided on the panel for adding a 2 pole Residual Current Device RCD to protect the 240V receptacle See Section F for instructions on installing an RCD 16 CIRCUIT BREAKER Single pole 20A rated Provides overload protec tion for the 120VAC 5 20R NEMA Duplex Receptacle BIG RED 600 LINCOLN B 4 17 18 19 20 21 22 120 VAC DUPLEX RECEPTACLE Single pole 20A rated Provides overload protec tion for the 120VAC 5 20R NEMA Duplex Receptacle CIRCUIT BREAKERS Single pole 15A rated Provides overload protection for the 120VAC European IEC 309 receptacle 120 VAC RECEPTACLE European IEC 309 receptacle rated up to 15 amps and is IP44 rated Receptacle is GFCI protected GFCI Ground Fault Circuit Interrupter Module Protects both 120VAC Auxiliary Power recepta cles If a GFCI Module is tripped See the MAINTE NANCE section for detailed information on testing and resetting the GFCI Module WELD OUTPUT TERMINALS
47. hind the engine door on the top of the engine 2 Remove air filter element 3 Remove loose dirt from element with compressed 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 around in the solution to help remove dirt 5 Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt 6 Dry element before reuse with warm air at less than 160 F 71 C Do not use light bulb to dry the ele ment 7 Inspect for holes and tears by looking through the element toward a bright light Check for damaged gaskets or dented metal parts Do not reuse dam aged elements Protect element from dust and damage during drying and storage 8 Reinstall air filter element After six cleanings replace air filter A cleaned filter will have approximately 70 of the life of a new fil ter element A restricted filter element may not appear excessively dirty FUEL At the end of each day s use refill the fuel tank to min imize moisture condensation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Use only fresh No 2D diesel fuel the use of No 1D diesel fuel is recommended in place of No 2D at tem peratures below 23
48. icio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas 5 3 8821 e e AHS xps Sy alll uuu i LG Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas o SIPH ERAL tE E 6487 6077 Li 655 95 ero Sel Aue 3433 ORY AIS 6 Vil ual la Ail gl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO SIR Chinese LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 5 88 60 88 5 gt 52 3788 EL TRMHOKRSMEI HVT FEU BA ET N LE PF BO ELE LR 6 5 REINA MARTRAHARSHRERE E34 oo 0 OXIME SHSAT EToMP HHE Saal cunas 38 gl
49. ides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed BIG RED 600 LINCOLN ES TROUBLESHOOTING ES Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Major Physical or Electrical Damage 1 Contact your Local Lincoln Engine will not crank Battery low Loose battery cable connections which may need Inspected cleaned or tighten Faulty wiring in engine starting circuit Faulty engine starter Contact authorized local Engine Service Shop Engine will crank but not start Out of fuel Fuel shut off valve is in the off If all recommended possible areas of position make sure the valve misadjustment have been checked lever is in a vertical direction and the problem persists Contact Engine shut down solenoid notlyour local Lincoln Authorized pulling in Field Service Facility On Off switch on for more than 60 sec before starting the On Off switch will need to
50. installed as a standby power unit for 240 VAC 60Hz Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapt ed to the particular installation and comply with all applicable electrical codes Take necessary steps to assure load is limited to the capacity of the BIG RED 600 A WARNING Only a licensed certified trained electrician should install the machine to a premises or resi dential electrical system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements BIG RED 600 LINCOLN 8 AT INSTALLATION A CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING 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 600 1 Shut the welder off 2 For electrode Positive connect the electrode cable from the wire feeder to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the elec trode cable from the wire feeder to the terminal of the welder and work cable to the
51. ion BIG RED 600 LINCOLN 0 OPERATION AUXILIARY 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 TABLE B 4 BIG RED 600 Simultaneous Welding and Power Loads 1 PHASE 120V T PHASE 240V PLUS TABLE B 5 BIG RED 600 Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Maximum Allowable Cord Length in ft m for Conductor Size Watts 240 360 Conductor size is based on maximum 2 0 voltage drop BIG RED 600 LINCOLN ACCESSORIES OPTIONAL FEATURES 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 local laws regarding possible additional requirements Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combi nation hitch Order K2636 1 Trailer K2639 1 Fender amp Light Kit K2640 1 Cable Storage Rack K704 ACCESSORY SET Includes 35 ft 10m of electrode cable and 30 ft 9 1m of work cable head shield
52. lammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged
53. lding Operation sienne B 5 ld B 5 GOUGING ee E B 5 B 6 Constant Current Operation with Lincoln Wire Feeder B 7 Auxiliary mea lai Ra Wheeled B 8 Simultaneous Welding and Power Loads B 8 ACCeSSOrIeS Section C Optional 0310 1 vii TABLE OF CONTENTS vii Page Section D riae D 1 Routine and Periodic Engine Maintenance D 1 Oil Fiter Changes EN D 2 Ximena EE D 2 Fuel and Bleeding the Fuel System D 2 Fuel E D 3 Fuel Pre Filter Water Separator Assembly 3 Water nsina aa aa e A t D 3 Second Fuel Filler roter Remi dn D 4 Cooling SYSIEM D 4 Cooling Blower Belt D 4 Battery odeur ente nte D 4 thru D 5 Servicing Optional Spark 2 2 4402 400 D 5 Nameplates Warning D 5 Welder Generator Maintenance D 6 Storage UE D 6 D 6 Brush Removal and Replacement aa D 6 GFCI Module Testin
54. lding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 8 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 LINCOLN 8 material to protect your skin and that of your helpers from the arc rays 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 FUMES AND GASES
55. ment au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes 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
56. mizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables INSTALLATION TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES AMPS Up to 150 ft 150 200 ft 200 250 ft 100 Up to 45m 45 60m 60 75m Duty Cycle 500 3 0 AWG 3 0 AWG 4 0 AWG 95mm2 95mm2 120mm2 A 5 MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must a be grounded to the frame of the welder using a grounding type plug or b be double insulated When this welder is mounted on a truck or trailer its frame must be securely connected to the metal frame of the vehicle When this engine driven welder is con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled Standby Power Connections as well as the article on grounding in the latest National Electrical Code and the local codes In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal ground stake going into the ground for at least 10 Feet or to the metal frame work of a building which has been
57. nd work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source SAFETY i ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel we
58. on electrodes and their proper application see www lincolnelectric com or the appropriate Lincoln publication WELDING MODE Set the Welding mode switch for the desired process either Stick Gouging or TIG CONSTANT CURRENT STICK WELDING CAUTION DO NOT TURN THE OUTPUT RANGE SELEC TOR WHILE WELDING because the current may arc between the contacts and damage the switch The Output Range Selector provides five overlap ping current ranges The Output Current Adjustment adjusts the current from minimum to maximum within each range Open circuit voltage is also controlled by the Output Current Adjustment permitting control of the arc characteristics A high open circuit voltage setting provides the soft buttering arc with best resistance to pop outs pre ferred for most welding To get this characteristic set the Output Range Selector to the lowest set ting that still provides the current you need and set the Ouput Current Adjustment near maximum For example to obtain 175 amps and a soft arc set the Output Range Selector to the 105 220 position and then adjust the Output Current Adjustment to get 175 amps When a forceful digging arc is required usually for vertical and overhead welding use a higher Output Range Selector setting and lower open circuit volt age For example to obtain 175 amps and a forceful arc set the Output Range Selector to
59. onnect nega tive lead to engine foot dE BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery PREVENTING ELECTRICAL DAMAGE 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging cir cuit The positive battery cable has a red termi nal cover If the battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last PREVENTING BATTERY DISCHARGE Turn off the RUN STOP to stop when engine is not running BIG RED 600 LINCOLN 5 D 5 PREVENTING BATTERY BUCKLING SERVICING OPTIONAL SPARK Tighten nuts on battery clamp until snug ARRESTOR CHARGING THE BATTERY pa When you charge jump replace or otherwise connect bat A WARNING tery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The MUFFLER MAY BE HOT Vantage positive battery terminal has a red terminal cover ALLOW ENGINE COOL BEFORE INSTALLING THE SPAR
60. own out with compressed air or steam to main tain proper cooling See the engine Owners Manual for procedures and frequency BATTERY CONNECTION A WARNING GASES FROM BATTERY can explode K Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to nega tive battery lead at engine foot IMPORTANT prevent ELECTRICAL DAMAGE WHEN a Installing new batteries BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery b Using a booster Use correct polarity Negative Ground The BIG RED 600 is shipped with the negative bat tery cable disconnected Before you operate the machine make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative battery terminal Remove the insulating cap from the negative battery terminal Replace and tighten negative battery cable terminal NOTE This machine is furnished with a wet cha
61. r product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI module is not work ing properly or has been incorrectly installed mis wired If your GFCI module is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI module if neces sary or replace the device BIG RED 600 LINCOLN E TROUBLESHOOTING xi HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column prov
62. r arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 Also see item 1 b Jan 09 SAFETY gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available WELDING and CUTTING Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause f
63. re typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles BIG RED 600 LINCOLN B 7 OPERATION B 7 CONSTANT CURRENT OPERATION 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 Most semiautomatic welding processes perform better using constant voltage power sources Welding codes usually do not address the power source selection or specifically whether the welding process is to be operated in the constant voltage or constant current mode Instead codes typically specify limitations on the current voltage heat input and preheat tempera ture based on the material to be welded The intention is to assure that proper weld material properties will develop Welding is sometimes performed using con stant current power sources The operation can be more convenient because it may allow the use of an existing stick SMAW power source and the power source can be placed at a distant location without any provision for adjusting the output settings For constant current operation the power source is set to deliver the specified current The power source regulates this current regardless of changes in the welding circuit incl
64. rged Faulty battery If all recommended possible areas of Faulty engine alternator misadjustment have been checked Loose or broken lead in charging and the problem persists Contact circuit your local Lincoln Authorized Loose fan belt may need tighten Field Service Facility ing No welding output Broken lead in weld rotor circuits Faulty field diode module Faulty weld rotor Open Breaker Check that selector switch is in position Welder has some no output and no 1 Faulty remote kit control Auxiliary output OK Faulty output control Rheostat Faulty output control wiring No auxiliary power Open breakers Faulty receptacle Faulty auxiliary circuit wiring GFCI Module tripped See Maintenance Section Broken Lead in Auxiliary rotor cir cuit Faulty Auxiliary Rotor field Diode module Faulty weld rotor 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 BIG RED 600 LINCOLN 8 p DIAGRAMS Fr INSTRUCTIONS FOR INSTALLING A 2 POLE RESIDUAL CURRENT DEVICE TO PROTECT THE 240V SINGLE PHASE RECEPTACLE Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install SHOCK us
65. rged battery if unused for several months the battery may require a booster charge Be sure to use the correct polarity when charging the battery BIG RED 600 LINCOLN 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 SPARK ARRESTOR Some federal state or local laws may require that petrol or diesel engines be equipped with exhaust spark arrestors when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrestor When required by local regulations a suitable spark arrestor must be installed and properly maintained CAUTION An incorrect arrestor may lead to damage to the engine or adversely affect performance WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tates the polarity of the electrode cable These con nections should be checked periodically and tightened if necessary Listed in Table A 1 are copper cable sizes recom mended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of mini
66. se and valve in bottom of base and pull through the hole in the case back or side of base on the welder Remove the cap from the drain valve Push valve in and twist counterclockwise Pull to open and drain the oil into a suitable container for disposal Close the drain valve by pushing in and twisting clockwise Replace the cap Re fill the crankcase to the upper limit mark on the dipstick with the recommended oil see engine oper ation manual OR engine service items decal OR below Replace and tighten the oil filler cap secure ly Push oil drain hose and valve back into unit re con nect negative battery cable and close doors and engine top cover before restarting unit Wash your hands with soap and water after handling used motor oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclama tion DO NOT throw it in the trash pour it on the ground or down a drain BIG RED 600 LINCOLN Le MAINTENANCE D 2 Use motor oil designed for diesel engines that meets requirements for API service classification CC CD CE CF CF 4 CG 4 or CH 4 ACEA E1 E2 E3 Always check the API service label on the oil container to be sure it includes the letters indicated Note An S grade oil must not be used in a diesel engine or damage may result It IS permissible to use an oil that meets S and C grad
67. t is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For maximum rating derate the welder output 5 for every 300 meters 984 ft above 1500 meters 4920 ft For output of 500A and below derate the welder output 5 for every 300 meters 984 ft above 2100 meters 6888 ft Contact a Deutz Service Representative for any engine adjustments that may be required HIGH TEMPERATURE OPERATION TEMPERATURES ABOVE 40 C AMPS DUTY CYCLE VOLTS TEMPERATURE 55 C 50 C 45 C 450 DC 30 38 500 DC 30 40 550 DC 30 34 BIG RED 600 LINCOLN es INSTALLATION 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 factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trail
68. turer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 SAFETY PRECAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension d
69. uding cable length electrode diam eter wire feed speed contact tip to work distance etc Changes in the wire feed speed WFS or contact tip to work distance CTWD affect the arc voltage when constant current power sources are used Lowering the wire feed speed raises the voltage raising the wire feed speed lowers the voltage Lengthening the contact tip to work distance raises the voltage short ening the contact tip to work distance lowers the volt age If the contact tip to work distance is properly maintained a satisfactory operating voltage range may be achieved and a sound weld may result However when a welder uses a longer contact tip to work distance an arc sensing wire feeder compen sates by increasing the wire feed speed to regulate the voltage Even if the voltage and current remain unchanged the increased wire feed speed may result in a deposition rate well beyond the specified range of the electrode Under these conditions the specified weld metal prop erties may not be achieved Constant voltage power sources deliver large current surges to stabilize the arc when the electrode is shorted or the arc length is very short However a constant current power source does not provide such a response to stabilize the arc It may be difficult to achieve required weld metal properties or to achieve the required quality of welds needed to pass nondestructive tests when such welds are made under constant current operat
70. your BIG RED 600 A WARNING Do not attempt to use this equipment until you have thoroughly read all operating and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 23 Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine MOVING PARTS injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should operate this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these pro vide maximum protection from moving parts and insure proper cooling air flow 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 gen erator can be used to provide electricity

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