RETURN TO MAIN MENU BIG RED™ 500 For use with machines having Code Numbers: IM10025-A March 2013 11585, 11871 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.
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 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 ARC WELDING CAN BE HAZARDOUS.
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.
iii iii SAFETY 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 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.
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 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.
v Thank You v 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! CUSTOMER ASSISTANCE POLICY 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.
vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Location and Ventilation ........................................................
vii vii 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 ..
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - BIG RED™ 500 (K2810-1) INPUT - DIESEL ENGINE Make/Model Deutz D2011L03i Diesel Engine EPA Tier 4i Compliant Description Speed (RPM) 3 cylinder 32HP (24 kw) @ 1800 RPM Displacement Idle 1890 125 cu. in (2.05L) Starting System Capacities 12VDC battery & Starter Full Load 1800 Fuel (20 US gal) 75.7L Bore x Stroke Oil: 6.3 QTS. 6.0L 3.89" x 4.
A-2 A-2 INSTALLATION SAFETY PRECAUTION ANGLE OF OPERATION 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.
A-3 A-3 INSTALLATION TOWING PRE-OPERATION ENGINE SERVICE 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.
A-4 A-4 INSTALLATION ENGINE BREAK-IN BATTERY CONNECTION 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.
A-5 INSTALLATION A-5 MUFFLER OUTLET PIPE MACHINE GROUNDING 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. 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.).
A-6 A-6 INSTALLATION AUXILIARY POWER RECEPTACLES RESIDUAL CURRENT DEVICE READY 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. The BIG RED™ 500 is configured to allow for the addition of a Residual Current Device (RCD) to protect the 240V Single Phase Receptacle.
A-7 A-7 INSTALLATION WARNING CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off Welder before making any electrical connections. -----------------------------------------------------------------------The LN-15™ Across-the-Arc model, LN-25™ with or without an internal contactor, and LN-25™ PRO may be used with the BIG RED™ 500. 1. Shut the welder off. 2.
B-1 OPERATION B-1 SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operating your BIG RED™ 500. 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™ 500 is both a rugged three cylinder, diesel engine driven 500 amp DC arc welder and 3.6 KW AC power generator.
B-2 B-2 OPERATION 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 3 10 4 11 2 1 5 9 8 7 6 13 12 14 20 15 16 17 18 19 22 21 2. OUTPUT CONTROL WELDING CONTROLS (Items 1-5) 1.
B-3 OPERATION 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) 6.
B-4 B-4 OPERATION 17. 120 VAC DUPLEX RECEPTACLE 120VAC (5-20R) NEMA Duplex Receptacle. Receptacle is GFCI protected. 18. CIRCUIT BREAKERS 8. Allow the engine to warm up for several minutes before applying a load. Allow a longer warm up time in cold weather. COLD WEATHER STARTING 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 protected.
B-5 B-5 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 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.
B-6 B-6 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.
B-7 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.
B-8 B-8 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.
C-1 ACCESSORIES OPTIONAL FEATURES K2641-2 FOUR WHEELED STEERABLE YARD TRAILER For in plant and yard towing. Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination Hitch. K2636-1 TRAILER - Two-wheeled trailer with optional fender and light package. For highway use, consult applicable federal, state, and local laws regarding possible additional requirements. Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination hitch.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 WEEKLY WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. Do not put your hands near the engine cooling blower fan.
D-2 MAINTENANCE Use motor oil designed for diesel engines that meets requirements for API service classification CC/CD/CE/CF/CF-4/CG-4 or CH-4. ACEA E1/E2/E3. Always check the API service label on the oil container to be sure it includes the letters indicated. (Note: An S-grade oil must not be used in a diesel engine or damage may result. It IS permissible to use an oil that meets S and C grade service classifications.) SAE 10W30 is recommended for general, all temperature use, 5F to 104F (-15C to 40C).
D-3 MAINTENANCE D-3 BATTERY HANDLING FUEL FILTERS WARNING When working on the fuel system • Keep naked lights away, do not smoke ! • Do not spill fuel ! -----------------------------------------------------------------------The BIG RED™ 500 is equipped with a Fuel Filter/Water Separator Assembly located after the lift pump and before the fuel injectors. The Fuel Filter/Water Separator is mounted to the engine block just left of the lift pump. 1. Close the fuel shutoff valve. 2.
D-4 MAINTENANCE D-4 SERVICING OPTIONAL SPARK ARRESTOR PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug. Clean every 100 hours. CHARGING THE BATTERY When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The Vantage positive (+) battery terminal has a red terminal cover.
D-5 MAINTENANCE WELDER / GENERATOR MAINTENANCE STORAGE Store the BIG RED™ 500 in clean, dry protected areas. CLEANING Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary. WARNING Do not attempt to polish slip rings while the engine is running.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE Major Physical or Electrical Damage 1. Contact your Local Lincoln is Evident. Authorized Field Service Facility. Engine will not crank 1. Battery low. 2. Loose battery cable connections which may need Inspected, cleaned or tighten. 3. Faulty wiring in engine starting circuit. 4. Faulty engine starter. Contact authorized local Engine Service Shop. Engine will crank but not start. 1.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Engine shuts down while under a 1. High oil temperature. load. Engine runs rough. 1. Dirty fuel or air filters may need cleaned/replaced. 2. Water in fuel. 3. Fuel injector clogged or malfunctioning. Engine will not shut off 1. Fuel Shutdown solenoid not functioning properly / linkage binding. Battery does not stay charged. 1. Faulty battery . 2.
F-1 F-1 DIAGRAMS INSTRUCTIONS FOR INSTALLING A 2-POLE RESIDUAL CURRENT DEVICE TO PROTECT THE 240V SINGLE PHASE RECEPTACLE WARNING Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts ELECTRIC SHOCK CAN KILL Only qualified persons should install, use or service this equipment 1. TURN OFF THE ENGINE AND DISCONNECT THE NEGATIVE BATTERY CABLE. 2. REMOVE THE SCREWS THAT SECURE THE LOWER CONTROL PANEL AND OPEN THE PANEL. 3.
F-2 F-2 DIAGRAMS 4. 5. LOCATE LEADS 3D & 6J. (SEE FIGURE 2). CUT BOTH LEADS AS SHOWN. STRIP ALL FOUR LEADS 13MM (.50 in.) CUT LEADS 240V RECEPTACLE 3D 6J 3D 6J FIGURE 2 RCD OPENING 6. CONNECT LEADS FROM CIRCUIT BREAKER & RECEPTACE TO RCD AS SHOWN & TIGHTEN LEADS TO 2.4NM (21 in-lb). (SEE FIGURE 3). NOTE LEAD CONFIGURATION. COAT AREA WHERE LEADS CONNECT TO RCD WITH A SILICONE RUBBER RTV SEALANT. 7. MOUNT RCD & PROTECTIVE BOOT TO PANEL USING MOUNTING BRACKET & SCREWS SET ASIDE IN STEP 3.
F-3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
BIG RED™ 500 30.00 762 27.00 685.8 28.82 732 6.29 159.8 1.28 32.5 36.87 936.6 39.84 1011.8 N.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK. 10.01 254.3 14.10 358.1 23.32 592.2 33.75 857.2 31.70 805.2 65.10 1653.7 59.50 1511.3 N.A. A.01 M22252 46.50 1181.
Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Keep flammable materials away. Wear eye, ear and body protection. Mantenga el material combustible Protéjase los ojos, los oídos y el electrode with skin or wet clothing. Insulate yourself from work and ground. No toque las partes o los electrodos bajo carga con la piel o ropa mojada. Aislese del trabajo y de la tierra.
Keep your head out of fumes. Use ventilation or exhaust to Turn power off before servicing. Do not operate with panel open or guards off. remove fumes from breathing zone. Los humos fuera de la zona de res- piración. Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. Gardez la tête à l’écart des fumées. Utilisez un ventilateur ou un aspira- Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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