Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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 fumesoutdoors. ...
Page 3 - ii
ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resist...
Page 4 - iii; Refer to
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ‘93 PRÉCAUTIONS 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 contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You 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...
Page 7 - TABLE OF CONTENTS
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 8 - vii
Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1Routine and Periodic Engine Maintenance ..................
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS - BIG REDTM 600; Description; INPUT - DIESEL ENGINE
A-1 INSTALLATION BIG RED™ 600 A-1 TECHNICAL SPECIFICATIONS - BIG RED™ 600 (K2811-1) 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...
Page 10 - SAFETY PRECAUTION
A-2 INSTALLATION BIG RED™ 600 A-2 SAFETY PRECAUTION Read this entire installation section before you startinstallation. LOCATION AND VENTILATION The welder should be located to provide an unrestrict-ed flow of clean, cool air to the cooling air inlets and toavoid restricting the cooling air outlets....
Page 11 - TOWING; VEHICLE MOUNTING; Stop engine while fueling.; DIESEL FUEL ONLY; OIL
A-3 INSTALLATION 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 mustassume responsibility that the method of attachmentand usage does not result in a safety hazard or dam...
Page 12 - ENGINE COOLING SYSTEM
A-4 INSTALLATION BIG RED™ 600 A-4 ENGINE BREAK-IN Lincoln Electric selects high quality, heavy-duty indus-trial engines for the portable welding machines weoffer. While it is normal to see a small amount ofcrankcase oil consumption during initial operation,excessive oil use, wetstacking (oil or tar ...
Page 13 - MUFFLER OUTLET PIPE; CAUTION
A-5 INSTALLATION BIG RED™ 600 A-5 MUFFLER OUTLET PIPE Remove the plastic plug covering the muffler outlettube. Using the clamp provided secure the outlet pipeto the outlet tube with the pipe positioned such that itwill direct the exhaust in the desired position . SPARK ARRESTOR Some federal, state o...
Page 14 - AUXILIARY POWER RECEPTACLES; • Only a licensed, certified, trained electrician
A-6 INSTALLATION BIG RED™ 600 A-6 AUXILIARY POWER RECEPTACLES The auxiliary power of the BIG RED™ 600 consists ofSingle 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 pr...
Page 16 - OPERATION; GENERAL DESCRIPTION
B-1 OPERATION B-1 GENERAL DESCRIPTION The BIG RED™ 600 is a diesel engine driven welder,offering reliable DC arc welding performance, withoutstanding arc characteristics for all welding applica-tions. The BIG RED™ 600 is both a rugged threecylinder, diesel engine driven 600 amp DC arc welderand 3.6 ...
Page 17 - OUTPUT RANGE SELECTOR SWITCH; WELD MODE SELECTOR SWITCH; CONTROLS AND SETTINGS; Figure B.1 Case Front Panel Controls
B-2 OPERATION 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 Provides fine adjustment of the ...
Page 19 - ENGINE OPERATION; STARTING THE ENGINE
B-4 OPERATION B-4 17. 120 VAC DUPLEX RECEPTACLE Single-pole 20A rated. Provides overload protec-t i o n f o r t h e 1 2 0 V A C ( 5 - 2 0 R ) N E M A D u p l e xReceptacle. 18. CIRCUIT BREAKERS Single pole 15A rated. Provides overload protectionfor the 120VAC European (IEC-309) receptacle. 19. 120 V...
Page 20 - WELDER OPERATION; DUTY CYCLE; WELDING MODE
B-5 OPERATION B-5 WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load isbeing applied in a 10 minute period. For example a60% duty cycle, represents 6 minutes of load and 4minutes of no load in a 10 minute period. ELECTRODE INFORMATION The BIG RED™ 600 is designed for horizonta...
Page 21 - TIG
B-6 OPERATION B-6 TIG The BIG RED™ 600 can be used for Scratch-Startof DC TIG welding applications. U s e t h e “ O u t p u t R a n g e S e l e c t o r ” a n d “ O u t p u tControl Adjustments” to set the desired current. Toi n i t i a t e a w e l d , t h e t u n g s t e n e l e c t r o d e i s t h ...
Page 23 - Simultaneous Welding and Auxiliary Power Loads; Simultaneous Welding and Power Loads; Extension Cord Length Recommendations
B-8 OPERATION B-8 BIG RED™ 600 AUXILIARY POWER: The auxiliary power is independent of the weldingpower 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 spe...
Page 24 - ACCESSORIES; OPTIONAL FEATURES
C-1 ACCESSORIES C-1 BIG RED™ 600 OPTIONAL FEATURES K2641-2 FOUR WHEELED STEERABLE YARDTRAILER For in plant and yard towing. Comes standard with aDuo-Hitch™, a 2” Ball and Lunette Eye combinationHitch. K2636-1 TRAILER - Two-wheeled trailer with optional fender and light package. For highway use, cons...
Page 25 - MAINTENANCE; SAFETY PRECAUTIONS; electrode with skin or wet clothing.; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n; ROUTINE AND PERIODIC MAINTENANCE; DAILY; ENGINE MAINTENANCE; ENGINE OIL CHANGE
D-1 MAINTENANCE D-1 BIG RED™ 600 SAFETY PRECAUTIONS Have qualified personnel do the maintenancework. Turn the engine off before working insidet h e m a c h i n e . I n s o m e c a s e s , i t m a y b enecessary to remove safety guards to performrequired maintenance. Remove guards onlyw h e n n e c e...
Page 26 - FUEL; AIR FILTER
D-2 MAINTENANCE D-2 3. Remove loose dirt from element with compressed air or water hose directed from inside out. Compressed Air: 100 psi maximum with nozzles a t l e a s t o n e i n c h a w a y f r o melement. Water Hose: 40 psi maximum without nozzle. 4. Soak element in a mild detergent solution f...
Page 27 - FUEL FILTERS; When working on the fuel system; WATER SEPARATOR ELEMENT
D-3 MAINTENANCE D-3 FUEL FILTERS When working on the fuel system • K e e p n a k e d l i g h t s a w a y , d o n o t smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The BIG RED™ 600 is equipped with a Fuel Pre-Filter/Water Separator Assembly loc...
Page 29 - PREVENTING BATTERY BUCKLING
D-5 MAINTENANCE D-5 PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug. CHARGING THE BATTERY 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. TheVantage positive (...
Page 30 - WELDER / GENERATOR MAINTENANCE; STORAGE; CLEANING
D-6 MAINTENANCE D-6 WELDER / GENERATOR MAINTENANCE STORAGE Store the BIG RED™ 600 in clean, dry protected areas. CLEANING Blow out the generator and controls periodically with lowpressure air. Do this at least once a week in particularly dirtyareas. BRUSH REMOVAL AND REPLACEMENT It is normal for the...
Page 31 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING 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. CAUTION This Troubleshooting G...
Page 32 - PROBLEMS; Contact
E-2 TROUBLESHOOTING 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...
Page 34 - DIAGRAMS; ELECTRIC; TU RN OFF TH E ENGIN E AND DI SCONN EC T TH E NEGATI VE BATTER Y CABLE.; INSTRUCTIONS FOR INSTALLING A 2-POLE RESIDUAL CURRENT DEVICE; COVER PLATE
F-1 DIAGRAMS F-1 BIG RED™ 600 A M22253 ELECTRIC SHOCK CAN KILL WARNING Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install,use or service this equipment 1. TU RN OFF TH E ENGIN E AND DI SCONN EC T TH E ...
Page 35 - C ONFI GURAT ION. COAT AR EA WH ER E LEADS C ONNEC T TO R CD WIT H A; T HE U NIT I S NOW READY FOR OPER AT ION; FIGURE 2
F-2 DIAGRAMS F-2 BIG RED™ 600 M22253 A 4. LOCATE LEADS 3D & 6J. (SEE FIGURE 2). CUT BOTH LEADS AS SHOWN. 5. ST RIP ALL FOUR LEADS 13MM (.50 in.) 6. C ONNECT LEADS FROM CI RC UIT BREAKER & REC EPT ACE T O RC D AS SH OW N & TI GH TEN LEAD S T O 2.4NM (21 in-lb). (SEE F IGUR E 3). NOT E LEA...
Page 38 - NOTES