Lincoln Electric IM10019 User Manual

™

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BIG RED 600

IM10019

August, 2009

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your ov e r a l l s a f e t y c a n b e
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.

11599

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

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

i

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 s ome ca ses it ma y be nece ssary to re mov e safety

gu a r d s t o perfo r m requ i r e d m a i ntena n c e . R e m ove
guards only when necessary and replace them when the
ma i n t e nance requ i r i n g th e ir re m oval is co m plete .
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.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 a ny cond uc to r cau se s
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields aro un d w el di ng cables and
welding machines

2.b. EMF fi elds m ay int er fere w ith some pa cemak ers, a nd
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. Ne ver coil th e ele ctrod e lead around yo ur bod y.

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.

___________________________________________________

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.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.

Mar ‘95

ii

SAFETY

ii

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 . W ear dry , h ole-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
mu s t be perfor med un der el ectrica l ly ha z ardous
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, noz zl e or semiaut om at ic
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. Nev er s imu lta neo usly t ouc h elec tri cal ly “ hot ” part s 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. Weldin g may produce fumes and gases
hazardous to health. Avoid breathing these
fumes a nd ga ses. When w el ding, 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

we l ding with elec trodes whic h r e quire spec i al
ve n tilati on such as st ainles s or hard fac ing (see
instru ctio ns on container or MS DS) 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 circum­st a nces, outd o ors, a resp i rator may be requir e d.
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.

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

caus e injury or deat h. Alw ays use eno ugh vent ilation ,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t e r i al safe t y d a ta shee t ( M S D S) and fo l l o w your
employer’s safety practices. MSDS forms are available from
yo u r w e lding d i s tribut o r o r from t h e m anufa c t u rer.

5.f. Also see item 1.b.

Jan ‘09

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m e m b er th a t w eldin g s p arks an d h ot
materials from welding can easily go through small cracks
an d op enin gs t o ad j ace nt areas . Av oid wel d ing nea r
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 informati on 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
Co n t a i ners a n d Pipi n g That H a v e Hel d H a zardo u s
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 pas si ng
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.

the w elding s parks from st arting a fi re.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. U se o n ly c o m press e d ga s c y l inder s
containing the correct shielding gas for the
pr o c e s s u s e d a n d p r o p erly opera t i n g
re g u l a tors desi g n e d fo r th e ga s an d

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

7.b. Alw ays keep cy linde rs i n an uprigh t positi on sec urely
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 an d fo llo w th e inst ruct ion s on co mpr essed 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.

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 equipmen t in accordance with the U.S . National
Electrical Code, all local codes a nd the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s 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.

Jan ‘09

iv

SAFETY

iv

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 L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

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

b. Faire trés attention de bien s’isoler de la masse quand on

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

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

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

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

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 s’applicuent 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 n’importe quelle partie
du corps.

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

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

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accid en ta l p eu t p ro voquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

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
d’o pérations de dégraissage, n ettoyage ou pistolage. La
chaleur ou les rayons de l’arc 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

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’au tre personnel t ravaillan t à pr oximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes d e laitier en f usion sont émises de l’a rc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité 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, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

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

Mar. ‘93

Thank You

vv

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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. 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 posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

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.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions........................................................................................................A-2

Location and Ventilation................................................................................................A-2

Storing...........................................................................................................................A-2

Stacking ........................................................................................................................A-2

Angle of Operation ........................................................................................................A-2

Lifting.............................................................................................................................A-2

High Altitude Operation.................................................................................................A-2

High temperature Operation..........................................................................................A-2

Towing...........................................................................................................................A-3

Vehicle Mounting...........................................................................................................A-3

Pre-Operation Engine Service..............................................................................................A-3

Oil..................................................................................................................................A-3

Fuel ...............................................................................................................................A-3

Engine Break-In ............................................................................................................A-4

Engine Coolant..............................................................................................................A-4

Battery Connection........................................................................................................A-4

Muffler Outlet Pipe ........................................................................................................A-5

Spark Arrester ...............................................................................................................A-5

Welding Output Cables ........................................................................................................A-5

Auxiliary Power Receptacles, Residual Device Ready, Standby Power Connections .........A-6

Connection of Lincoln Electric Wire Feeders .......................................................................A-7

________________________________________________________________________________

vi

Operation.........................................................................................................................Section B

Safety Instructions................................................................................................................B-1

General Description..............................................................................................................B-1

Recommended Applications.................................................................................................B-1

Controls and Settings ..................................................................................................................B-2

Welder Controls ............................................................................................................B-2

Engine Controls.............................................................................................................B-3

Auxiliary.........................................................................................................................B-3

Engine Operation .................................................................................................................B-4

Starting the Engine........................................................................................................B-4

Cold Weather Starting and Operation ...........................................................................B-4

Stoping the Engine........................................................................................................B-4

Welding Operation................................................................................................................B-5

Stick ..............................................................................................................................B-5

Arc Gouging ..................................................................................................................B-5

TIG Welding ..................................................................................................................B-6

Constant Current Operation with Lincoln Wire Feeder .................................................B-7

Auxiliary Power.....................................................................................................................B-8

Simultaneous Welding and Power Loads .....................................................................B-8

________________________________________________________________________________

Accessories.....................................................................................................Section C

Optional Features ..................................................................................................C-1

________________________________________________________________________

TABLE OF CONTENTS

Page

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine and Periodic Engine Maintenance ...........................................................D-1

Oil Filter Change .............................................................................................D-2

Air Filter Change .............................................................................................D-2

Fuel and Bleeding the Fuel System ................................................................D-2

Fuel Filters ......................................................................................................D-3

Fuel Pre-Filter/Water Separator Assembly .....................................................D-3

Water Separator Element ...............................................................................D-3

Second Fuel Filter ...........................................................................................D-4

Cooling System ...............................................................................................D-4

Cooling Blower Belt.........................................................................................D-4

Battery Handling ...............................................................................D-4 thru D-5

Servicing Optional Spark Arrestor .........................................................................D-5

Nameplates / Warning Decals ........................................................................D-5

Welder / Generator Maintenance ..........................................................................D-6

Storage ...........................................................................................................D-6

Cleaning..........................................................................................................D-6

Brush Removal and Replacement ..................................................................D-6

GFCI Module Testing and Resetting Procedure .............................................D-6

________________________________________________________________________

viivii

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

________________________________________________________________________

Diagrams ..........................................................................................................Section F

Instructions for Installing a Residual Current Device......................................F-1, F-2

Wiring Diagram ......................................................................................................F-3

Dimension Print......................................................................................................F-4

________________________________________________________________________

Parts List...................................................................................................P-619 SERIES

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS - BIG RED™ 600

(K2811-1)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

Deutz 3 cylinder Idle 1890 173 cu. in 12VDC battery Fuel
F3L 912 44HP (33 kw) (2.83L) & Starter (20 US gal)
Diesel Engine @ 1800 RPM Full Load 1800 75.7L

Bore x Stroke

Oil:

3.94” x 4.72” 9.5 QTS.

(100mm x 120mm) 9.0L

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

Welding Process

DC Constant Current

TIG

Welding Output

Current/Voltage/Duty Cycle

500A / 40V / 100%

550A / 34V / 60%
600A / 30V / 40%

250A / 20V / 100%

Output Range

Amps

65A TO 600A
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

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.

in. 28.28 in 65.1 in.

1657 lbs. (752 kg.)

BIG RED™ 600

A-2

INSTALLATION

A-2

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 operator’s 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

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 1772lbs.
(804kg.) with a full tank of fuel 1657lbs.(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 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.

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

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 can’t 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 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.

BIG RED™ 600

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

WELDER OUTPUT RATINGS AT

TEMPERATURES ABOVE 40°C

AMPS DUTY CYCLE VOLTS TEMPERATURE

450 DC 30% 38 55°C
500 DC 30% 40 50°C
550 DC 30% 34 45°C

A-3

INSTALLATION

A-3

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; rough-

ness 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 manufacture’s 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 expan­sion may cause overflow.

DIESEL FUEL ONLY

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

OIL

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 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 Operator’s Manual for the proper service and
maintenance intervals. The machine is equipped with
an oil drain valve.

FUEL

USE DIESEL FUEL ONLY

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.

NOTE: A fuel shut off valve is located on the pre-

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

BIG RED™ 600

WARNING

filter/sediment filter. Which should be in
the closed position when the welder is not
used for extended periods of time.

A-4

INSTALLATION

A-4

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 diesel­powered equipment needs only to be run at a reason­ably 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 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™ 600 is shipped with the negative bat­tery 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
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

A-5

INSTALLATION

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 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 Upto150 ft. 150-200 ft. 200-250 ft.

@100% (Up to45m) (45-60m) (60-75m)

Duty Cycle

500 3/0 AWG 3/0 AWG 4/0 AWG

95mm

AND WORK CABLES

2

95mm

2

120mm

2

BIG RED™ 600