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IM10019
™
August, 2009
BIG RED 600
For use with machines having Code Numbers: 11599
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATO
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Linco
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Location and Ventilation................................................
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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
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A-1 A-1 INSTALLATION 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 Welding Output Output Range Max. Weld OCV Current/Voltage/Du
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A-2 A-2 INSTALLATION SAFETY PRECAUTION ANGLE OF OPERATION Read this entire installation section before you start To achieve optimum engine performance the BIG installation. RED™ 600 should be run in a level position. The maximum angle of operation for the Deutz engine is WARNING 30 degrees fore and aft, 40 degrees right and 45 degrees left. If the engine is to be operated at an ELECTRIC SHOCK can kill. angle, provisions must be made for checking and • Do not touch electrically live parts or main
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A-3 A-3 INSTALLATION TOWING PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- Use a recommended trailer for use with this equip- tions supplied with this machine. ment for road, in-plant and yard towing by a vehi- cle(1). If the user adapts a non-Lincoln trailer, he must WARNING assume responsibility that the method of attachment and usage does not result in a safety hazard or dam- age the welding equipment. Some of the factors to be Stop engine while fueling. consi
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A-4 A-4 INSTALLATION ENGINE BREAK-IN BATTERY CONNECTION Lincoln Electric selects high quality, heavy-duty indus- WARNING trial engines for the portable welding machines we GASES FROM BATTERY can explode. offer. While it is normal to see a small amount of • Keep sparks, flame and cigarettes crankcase oil consumption during initial operation, away from battery. excessive oil use, wetstacking (oil or tar like sub- stance at the exhaust port), or excessive smoke is not To prevent EXPLOSION when: nor
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A-5 A-5 INSTALLATION MUFFLER OUTLET PIPE MACHINE GROUNDING Remove the plastic plug covering the muffler outlet Because this portable engine driven welder creates its tube. Using the clamp provided secure the outlet pipe own power, it is not necessary to connect its frame to to the outlet tube with the pipe positioned such that it an earth ground, unless the machine is connected to will direct the exhaust in the desired position. premises wiring (home, shop, etc.). To prevent dangerous electric s
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A-6 A-6 INSTALLATION AUXILIARY POWER RECEPTACLES RESIDUAL CURRENT DEVICE READY The auxiliary power of the BIG RED™ 600 consists of The BIG RED™ 600 is configured to allow for the Single Phase 60Hz Power. Out put Voltage is within addition of a Residual Current Device (RCD) to pro- +/- 10% at loads up to rated capacity. tect the 240V Single Phase Receptacle. The auxiliary power area on the front panel of the BIG RED™ 600 One 120VAC NEMA (5-20R) 20 amp duplex recepta- has a hole sized and shaped t
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A-7 A-7 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WARNING WIRE FEEDERS If you are using an LN-25™ without an internal contactor, the electrode will be energized when the BIG RED™ 600 is started. WARNING ------------------------------------------------------------------------ The Wire Feeder sensor has full OCV potential Shut off Welder before making any electrical con- between spring clip and work return. Turn nections. machine off when attaching spring clip. ----------------------------------
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B-1 B-1 OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before The BIG RED™ 600 is a diesel engine driven welder, operating your BIG RED™ 600. offering reliable DC arc welding performance, with outstanding arc characteristics for all welding applica- tions. The BIG RED™ 600 is both a rugged three WARNING cylinder, diesel engine driven 600 amp DC arc welder and 3.6 KW AC power generator. This powerful gen- Do not attempt to use this equipment until you er
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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 4 10 11 2 1 5 9 8 7 6 13 12 14 20 19 16 17 18 15 22 21 2. OUTPUT CONTROL WELDING CONTROLS (Items 1-5) Provides fine adjustment of the current and open 1. OUTPUT RANGE SELECTOR SWITCH circuit voltage from minimum to maximum within A 5 position switch that provides 5 overlapping out- each Range. put
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B-3 B-3 OPERATION 5. LOCAL / REMOTE CONTROL SWITCH and 11. OIL PRESSURE GAUGE REMOTE RECEPTACLE An indicator of engine oil pressure. The toggle switch provides the option of controlling 12. ENGINE PROTECTION the welding output at the control panel or remotely. A warning indicator light for high oil temperature or For control at the control panel set the switch in the low oil pressure. The light remains off with proper "LOCAL" position. For remote control set the switch oil temperature and proper
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B-4 B-4 OPERATION 17. 120 VAC DUPLEX RECEPTACLE 8. Allow the engine to warm up for several minutes before applying a load. Allow a longer warm up Single-pole 20A rated. Provides overload protec- time in cold weather. tion for the 120VAC (5-20R) NEMA Duplex Receptacle. COLD WEATHER STARTING 18. CIRCUIT BREAKERS With a fully charged battery and the proper weight Single pole 15A rated. Provides overload protection oil, the engine should start satisfactorily even down for the 120VAC European (IEC-30
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B-5 B-5 OPERATION For example: to obtain 175 amps and a forceful arc, WELDER OPERATION set the “Output Range Selector” to the 150-330 position and the “Output Current Adjustment” set- DUTY CYCLE ting to get 175 amps. Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example a Some arc instability may be experienced with 60% duty cycle, represents 6 minutes of load and 4 EXX10 electrodes when trying to operate with long minutes of no load in a 10 minute per
