Lincoln Electric BIG RED 500, BIG RED 600 Service Manual

BIG RED®500/600

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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 READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

SVM212-A

July, 2011

For use with machine code number: 11585, 11599

View Safety Info View Safety Info View Safety Info View Safety Info

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

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 & Cutting - ANSI Standard Z49.1” 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

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 vaporizing 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.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in 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.

____________________________________________________

1.e. 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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. 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 and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

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.g. 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.

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.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

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BIG RED®500/600

ii ii

SAFETY

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.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

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.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. 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 circumstances,
outdoors, a respirator may be required. Additional pre­cautions are also required when welding on galvanized
steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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BIG RED®500/600

iii iii

SAFETY

WELDING and CUTTING
SPARKS can cause fire or
explosion.

6.a.
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.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.

6.h. Also see item 1.c.

Remove fire hazards from the welding area.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders

If

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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BIG RED®500/600

iv iv

SAFETY

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 suiv­antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie du
corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

quʼun verre blanc afin de se protéger les yeux du rayon­nement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

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BIG RED®500/600

I I

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A, AA

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B, BB

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C, CC

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D, DD

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-619, P-620

BIG RED®500/600

II II

NOTES

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BIG RED®500/600

III III

NOTES

THIS SECTION FOR

BIG RED®500 ONLY.

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BIG RED®500/600

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

TABLE OF CONTENTS - INSTALLATION SECTION

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Location and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Welding Output Cables, Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Auxiliary Power Receptacles, Residual Device Ready, Standby Power Connections . . . . . . . . . . . . . . . . .A-7

Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

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BIG RED®500/600

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - BIG RED®500

(K2810-1)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

Deutz 3 cylinder Idle 1890 125 cu. in 12VDC battery Fuel
D2011L03i 32HP (24 kw) (2.05L) & Starter (20 US gal)
Diesel Engine @ 1800 RPM Full Load 1800 75.7L
EPA Tier 4i Bore x Stroke
Compliant Oil:

3.89" x 4.13" 6.3 QTS.

(99mm x 105mm) 6.0L

RATED OUTPUT @ 104° F (40° C) - WELDER

Welding Process

DC Constant Current

TIG

Welding Output

Current/Voltage/Duty Cycle

400A / 36V / 100%

450A / 34V / 60%
500A / 30V / 40%

250A / 20V / 100%

Output Range

Amps

65A TO 500A

65A TO 250A

Max. Weld OCV

Voltage @ 1800RPM

90 Volts

75 Volts

RATED OUTPUT @ 104° F (40° C).- GENERATOR

1

AMPS

20
15
15

POWER

2400 Watts
1800 Watts
3600 Watts

OUTLETS

1
1
1

Auxiliary Power

Single Phase 60 Hz AC

VOLTS

120
120
240

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

1 - 120VAC Duplex NEMA(5-20R) GFCI protected
1 - 120VAC European (IEC-309)-GFCI protected
1 - 240VAC European (IEC-309)

1 - 20 AMP for 120 VAC Duplex (NEMA)
1 - 15 AMP for 120 VAC
1 - 15 AMP for 240 VAC

European (IEC-309)

European (IEC-309)

20AMP for Battery Charging Circuit

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

(2)

36.87

936.5 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 9.63”(244.6mm) to top of exhaust pipe.

in. 28.28 in 65.1 in.

1538 lbs. (697 kg.)

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BIG RED®500/600

A-3 A-3

INSTALLATION

SAFETY PRECAUTION

Read this entire installation section before you start
installation.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• 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.

------------------------------------------------------------------------

MOVING PARTS can 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 operatorʼs manual.

LOCATION AND VENTILATION

The welder should be located to provide an unrestrict­ed 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 place when it is
not in use. Protect it from dust and dirt. Keep it
where it canʼt be accidentally damaged from con­struction 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 circulate
oil to all the parts. See the MAINTENANCE sec-

tion 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.

ANGLE OF OPERATION

To achieve optimum engine performance the BIG

®

500 should be run in a level position. The max-

RED
imum angle of operation for the Deutz engine is 20
degrees in direction of control panel angled up and 30
degrees for left, right and control panel angled down. 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®500 weighs approximately 1653lbs.
(750kg.) with a full tank of fuel 1538lbs.(697kg) 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 ade­quate lifting capacity.

• Be sure machine is stable when lift­ing.

• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • 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 400A 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

WELDER OUTPUT RATINGS AT

STACKING

AMPS DUTY CYCLE VOLTS TEMPERATURE

BIG RED®500 machines cannot be stacked.

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BIG RED®500/600

350 DC 30% 34 55
400 DC 30% 36 50
450 DC 30% 34 45

TEMPERATURES ABOVE 40°C

°

C

°

C

°

C

A-4 A-4

INSTALLATION

TOWING

Use a recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle(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 damage 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 trailer 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; rough­ness of surface on which the trailer will be operated;
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.

(1)

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 compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufactureʼs instructions.

------------------------------------------------------------------------

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instruc­tions supplied with this machine.

WARNING

Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from
tank.

• Do not leave unattended while

fueling.

DIESEL FUEL
can cause fire.

• 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

USE DIESEL FUEL ONLY - Low Sulphur fuel or ultra
low sulphur fuel in USA and CANADA only.

-----------------------------------------------------------------------------------------

OIL

The BIG RED®500 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 Operatorʼs Manual for specific 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 Operatorʼs
Manual for the proper service and maintenance inter­vals. The machine is equipped with an oil drain valve.

FUEL

WARNING

USE DIESEL FUEL ONLY - Low Sulphur fuel or ultra
low sulphur fuel in USA and CANADA only.

• 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.

WARNING

NOTE: A fuel shut off valve is located to the left of

the fuel lift pump and should be in the
closed position when the welder is not used
for extended periods of time.

------------------------------------------------------------------------

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BIG RED®500/600

A-5 A-5

INSTALLATION

ENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty indus­trial 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 substance
at the exhaust port), or excessive smoke is not normal.

Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load conditions
for extended periods of time are especially susceptible
to the conditions described above. To accomplish suc­cessful engine break-in, most diesel-powered equip­ment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engineʼs 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 suit­able resistive load bank. Note that any
attempt to short the output studs by con­necting 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 gener­ator and voids the warranty.

2. Set the welder controls for an output cur­rent 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 blown out with compressed air or steam to maintain
proper cooling (See the engine Owners Manual for
procedures and frequency).

BATTERY CONNECTION

WARNING

GASES FROM BATTERY can explode.

• 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 nega­tive battery lead at engine foot.

BATTERY ACID can burn eyes and skin.

• Wear gloves and eye protection and be
careful when working near battery.

• Follow instructions printed on battery.

IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:

a) Installing new batteries.
b) Using a booster.

Use correct polarity — Negative Ground.

------------------------------------------------------------------------

The BIG RED
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 charged

®

500 is shipped with the negative battery

battery; if unused for several months, the bat­tery may require a booster charge. Be sure to
use the correct polarity when charging the bat­tery.

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BIG RED®500/600

A-6 A-6

INSTALLATION

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 dic­tates the polarity of the electrode cable. These con­nections should be checked periodically and tightened
if necessary.

Listed in Table A.1 are copper cable sizes recom­mended 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 minimizing
cable voltage drop.

Table A.1 Combined Length of Electrode and Work
Cables.

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 con­nected 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 sec­tion 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 frame­work of a building which has been effectively ground­ed. The National Electric Code lists a number of alter­nate means of grounding electrical equipment. A
machine grounding stud marked with the symbol is
provided on the front of the welder.

TOTAL COMBINED LENGTH OF ELECTRODE

AMPS Up to 150 ft. 150-200 ft. 200-250 ft.

@100% (Up to 45m) (45-60m) (60-75m)

Duty Cycle

400 3/0 AWG 3/0 AWG 4/0 AWG

95mm

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AND WORK CABLES

2

95mm

2

120mm

2

BIG RED®500/600

A-7 A-7

INSTALLATION

AUXILIARY POWER RECEPTACLES

The auxiliary power of the BIG RED®500 consists of
Single Phase 60Hz Power. Output Voltage is within +/­10% at loads up to rated capacity.

One 120VAC NEMA (5-20R) 20 amp duplex receptacle
is protected by a 20 amp circuit breaker that provides
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 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 Continuous power. The 2-pole cir­cuit breaker disconnects both hot leads at the same
time. Maximum current is 15 amps.

120 VOLT RECEPTACLES

RESIDUAL CURRENT DEVICE READY

The BIG RED®500 is configured to allow for the addi­tion of a Residual Current Device (RCD) to protect the
240V Single Phase Receptacle. The auxiliary power
area on the front panel of the BIG RED
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 RCDʼs. One example is
Allen Bradley, part number 1492-RCD2A40.

The protective boot can be obtained from:
APM-Hexseal, part number HE-1035

See Section F Diagrams of the Operatorʼs Manual for
this machine for instructions on installing an RCD and
protective rubber boot.

®

500 has a

A GFCI module protects, the two 120V Auxiliary Power
receptacles. A GFCI (Ground Fault Circuit Interrupter)
electrical receptacle is a device to protect against elec-

tric 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 the MAINTENANCE section for
detailed information on testing and resetting 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.

STANDBY POWER CONNECTIONS

The BIG RED®500 is suitable for temporary, standby
or emergency power using the engine manufacturerʼs
recommended maintenance schedule.

The BIG RED®500 can be permanently 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 adapted 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

®

500

WARNING

• Only a licensed, certified, trained electrician
should install the machine to a premises or resi­dential 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.

------------------------------------------------------------------------

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BIG RED®500/600

A-8 A-8

BIG RED™ 500

Wor k

Electrode

Wo rk c lip

LN-15™ ACROSS THE ARC
LN-25™, LN-25™ PRO

NOTES

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

WARNING

Shut off Welder before making any electrical con­nections.

------------------------------------------------------------------------

®

The LN-15

Across-the-Arc model, LN-25

out an internal contactor, and LN-25

®

used with the BIG RED

500.

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 electrode cable
from the wire feeder to the “-” terminal of the welder
and work cable to the “+” 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 set­ting welding parameters).

®

with or with-

®

PRO may be

WARNING

®

If you are using an LN-25
tactor, the electrode will be energized when the

®

BIG RED

500 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.

------------------------------------------------------------------------

without an internal con-

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) cannot be

®

used with the BIG RED

500. See the appro-

priate connection diagram in Section F of the
Operatorʼs manual.

FIGURE A-1

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BIG RED®500/600

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

TABLE OF CONTENTS - OPERATION SECTION

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Cold Weather Starting and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Stoping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Constant Current Operation with Lincoln Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

Simultaneous Welding and Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

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BIG RED®500/600

B-2 B-2

OPERATION

SAFETY INSTRUCTIONS

Read and understand this entire section before
operating your BIG RED

®

500.

WARNING

Do not attempt to use this equipment until you
have thoroughly read all operating and mainte­nance 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.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside

• Do not stack anything near the engine.

------------------------------------------------------------------------

MOVING PARTS can 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

GENERAL DESCRIPTION

The BIG RED®500 is a diesel engine driven welder,
offering reliable DC arc welding performance, with out­standing arc characteristics for all welding applications.
The BIG RED
diesel engine driven 500 amp DC arc welder and 3.6
KW AC power generator. This powerful generator can
be used to provide electricity for lights, power tools,
etc.

The BIG RED®500 delivers ideal DC arc characteristic
for each welding process. Stick electrode welding,
Scratch-Start TIG, or carbon arc gouging, to make the
BIG RED®500 the ideal all purpose engine driven
welder for on-site work.

The BIG RED®500 has “no PC Boards” and “no elec­tronics”.

The BIG RED®500 is service friendly with a minimal
number of major parts, simplifying in field servicing of
the BIG RED®500. The generator is a dual stator and
rotor design with two sealed bearings for maintenance
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 environmentally
protective coating . These measures insure trouble­free operation in the harshest environments.

®

500 is both a rugged three cylinder,

RECOMMENDED APPLICATIONS

WELDER

The BIG RED
ing 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 8.0 mm (5/16”) diame­ter.

®

500 provides constant current DC weld-

Always operate the welder with the hinged door
closed and the side panels in place as these pro­vide maximum protection from moving parts and
insure proper cooling air flow.

------------------------------------------------------------------------

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BIG RED®500/600

The BIG RED®500 is not recommended for pipe
thawing.

GENERATOR

The BIG RED®500 provides smooth output for auxil­iary power and emergency standby power. The auxil­iary power 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.

B-3 B-3

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

OPERATION

1

9

8

7

6

14

3

4

10

11

2

5

13

12

20

15

WELDING CONTROLS (Items 1-5)

1. OUTPUT RANGE SELECTOR SWITCH

A 5 position switch that provides 5 overlapping out­put current settings:

• 65 - 115

• 105 - 220

• 150 - 330

• 200 - Maximum

NOTE: Do not switch while welding

16

17

18

19

22

21

2. OUTPUT CONTROL

Provides fine adjustment of the current and open
circuit voltage from minimum to maximum within
each Range.

“1ʼʼ is minimum and “10” is maximum.

3. WELD MODE SELECTOR SWITCH

Provides selection of either Stick / Arc Gouging
Mode or TIG Mode.

4. VOLT/AMP METERS (optional)

Optional analog volt and amp meter kit available for
easy installation into front panel.

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BIG RED®500/600

(See Accessory Section For “K” number)

B-4 B-4

5. LOCAL / REMOTE CONTROL SWITCH and
REMOTE RECEPTACLE

The toggle switch provides the option of controlling
the welding output at the control panel or remotely.
For control at the control panel set the switch in the
"LOCAL" position. For remote control set the switch
in the "REMOTE" position. The receptacle is for
attaching an optional remote control equipment.

(See Accessory Section For “K” number)

ENGINE CONTROLS (Items 6 Through to

13)

OPERATION

11. OIL PRESSURE GAUGE

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 pro­tection 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.

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 prevent
running out of fuel and possibly having to bleed the
system.

7. RUN STOP 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.

9. CIRCUIT BREAKER

The battery circuit breaker protects the engine cir­cuitry 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.

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 happens 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, the alternator
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 16
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 of
Operatorʼs Manual for instructions on installing
an RCD.

16. CIRCUIT BREAKER

Single-pole 20A rated. Provides overload protec­tion for the 120VAC (5-20R) NEMA Duplex
Receptacle.

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BIG RED®500/600

B-5 B-5

17. 120 VAC DUPLEX RECEPTACLE

Single-pole 20A rated. Provides overload protec­tion for the 120VAC (5-20R) NEMA Duplex

OPERATION

8. Allow the engine to warm up for several minutes
before applying a load. Allow a longer warm up time
in cold weather.

Receptacle.

18. CIRCUIT BREAKERS

Single pole 15A rated. Provides overload protec­tion for the 120VAC European (IEC-309) recepta­cle.

19. 120 VAC RECEPTACLE

European (IEC-309) receptacle rated up to 16
amps and is IP44 rated. Receptacle is GFCI pro-

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 frequent­ly started below -15°C(5°F), it may be desirable to
install additional starting aids. The use of No. 1D
diesel fuel is recommended in place of No. 2D at
temperatures below -5°C(23° F).

tected.

STOPPING THE ENGINE

20. GFCI (Ground Fault Circuit Interrupter) Module

Protects both 120VAC Auxiliary Power recepta­cles.

If a GFCI Module is tripped, See the MAINTE-
NANCE section for detailed information on testing
and resetting the GFCI Module.

Switch the RUN/STOP switch to “STOP”. This turns
off the voltage supplied to the shutdown solenoid. 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.

21. WELD OUTPUT TERMINALS + AND -

Covered terminals that provide welding connection
points for the electrode and work cables.

22. GROUND STUD

Protects both 120VAC Auxiliary Power recepta­cles.

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).

2. Check for proper oil level. Close engine compart­ment door.

3. Remove all plugs connected to the AC power recep­tacles.

4. 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).

5. Within 30 seconds, press and hold the engine
START button until the engine starts.

6. Release the engine START button when the engine
starts.

7. 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.

TABLE B.1

TYPICAL

High Idle - No Load
1890 R.P.M.
DC, CC Weld Output
400A/36V/100%
DC, CC Weld Output
500A/30V/40%

Auxiliary Power

3.6 Kw

BIG RED®500

Deutz D2011L03i Engine
32HP (24Kw) @ 1800 RPM

FUEL CONSUMPTION

2.1 liters/hr
(.56 gal/hr)

5.6 liters/hr

(1.49 gal/hr)

3.6 liters/hr
(.97 gal/hr)

2.6 liters/hr
(.69 gal/hr)

Running Time for

75.7 L (20 Gal.)

35.6 hrs

13.4 hrs

20.7 hrs

28.9 hrs

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.

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BIG RED®500/600

B-6 B-6

OPERATION

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
cal 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 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

®

500 is designed for horizontal, verti-

CAUTION

DO NOT TURN THE “OUTPUT RANGE SELECTOR”
WHILE WELDING because the current may arc
between the contacts and damage the switch.

------------------------------------------------------------------------

For example: to obtain 175 amps and a forceful arc,
set the “Output Range Selector” to the 150-330
position and the “Output Current Adjustment” setting
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

The “Output Range Selector” provides five overlap­ping 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 pre­ferred for most welding. To get this characteristic,
set the “Output Range Selector” to the lowest set­ting that still provides the current you need and set
the “Output 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 volt­age.

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BIG RED®500/600

1/4"(6.4mm) 300-400 Amps

5/16"(8.0mm) 350-500 Amps

B-7 B-7

OPERATION

TIG

The BIG RED®500 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

500. The
BIG RED®500 and any high frequency generating
equipment must be properly grounded. See the
K930-2 TIG Module operating manuals for complete
instructions on installation, operation, and mainte­nance.

When using the TIG Module, the OUTPUT control
on the BIG RED®500 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

Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel
Tungsten Tungsten

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)

0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)

1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6

3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

(1)

FOR TUNGSTEN ELECTRODES

(2)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or 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:

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures

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# 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)

and high duty cycles.

BIG RED®500/600

B-8 B-8

OPERATION

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 temperature
based on the material to be welded. The intention is to
assure that proper weld material properties will devel­op. Welding is sometimes performed using constant
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.

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 operation.

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, including cable length, electrode diameter,
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, shortening
the contact tip to work distance lowers the voltage. 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 compensates 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 prop­erties 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.

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BIG RED®500/600

B-9 B-9

OPERATION

AUXILIARY POWER:

The auxiliary power is independent of the welding
power and thus not effected by the weld control set­tings.

Simultaneous Welding and Auxiliary Power Loads

The auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified
in the following Table B.4.

TABLE B.4

BIG RED®500 Simultaneous Welding and Power Loads

Current

(Amps)

15
20
15

Voltage

Volts

120
120
240

Weld

Amps

0
100
200
300
400
500

PLUS

1 PHASE (120V)
WATTS AMPS

2400 20
2400 20
2400 20
1200 10

0 0
0 0

1 PHASE (240V)
WATTS AMPS

3600 15
3600 15

OR

2400 10
1200 5

0 0
0 0

TABLE B.5

BIG RED®500 Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Load

(Watts)

1800
2400
36003060

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

(9)

(18)

Conductor size is based on maximum 2.0% voltage drop.

Maximum Allowable Cord Length in ft. (m) for Conductor Size

40
30
75

(12)

(9)

(23)

75
50

150

(23)
(15)
(46)

125

88

225

(38)
(27)
(69)

175
138
350

(53)
(42)

(107)

300
225
600

(91)
(69)

(183)

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BIG RED®500/600

B-10 B-10

NOTES

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BIG RED®500/600

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

TABLE OF CONTENTS - ACCESSORIES SECTION

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BIG RED®500/600

C-2 C-2

ACCESSORIES

OPTIONAL FEATURES

K2641-2 FOUR WHEELED STEERABLE YARD
TRAILER

For in plant and yard towing. Comes standard with a
Duo-Hitch
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
hitch.

Order:
K2636-1 Trailer
K2639-1 Fender & 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, head­shield, 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 out­put control on the welder. Has a convenient twist-lock
plug for easy connection to the welder.

®

, a 2” Ball and Lunette Eye combination

®

, a 2” Ball and Lunette Eye combination

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.

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BIG RED®500/600

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Routine and Periodic Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

TABLE OF CONTENTS - MAINTENANCE SECTION

Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Air Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Fuel and Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5 thru D-6

Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6

Nameplates / Warning Decals Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6

Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7

Brush Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7

GFCI Module Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7

Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

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BIG RED®500/600

D-2 D-2

MAINTENANCE

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BIG RED®500/600