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Lincoln Electric BIG RED 500 Operator'S Manual Download Page 63

KEY

PART NUMBER

DESCRIPTION

QTY

1A

9SG8453

Roof

1

1B

9SS28142

CASE SIDE STIFFENER

1

9SS9225-64

SELF TAPPING SCREW

14

1D

9SM15045-107

ACOUSTICAL FOAM

1

2A

9SG8457

Right Case Side

1

9SS9225-64

SELF TAPPING SCREW

8

3A

9SG8476

Case Side

1

3B

9SS28142

CASE SIDE STIFFENER

1

9SS9262-98

PLAIN WASHER

4

9SE106A-2

LOCKWASHER

4

9SCF000017

1/4-20HN

4

9ST11525-7

SPEED NUT

1

9SS9225-64

SELF TAPPING SCREW

4

4A

9SG8475

Case Side

1

9SS9225-64

SELF TAPPING SCREW

8

9SS27368-6

LOGO DECAL

1

9SM22220

FAMILY NAME DECAL

1

9SL16911

Door Assembly

1

6A

9SL16910

Door Welded Assembly

1

6B

9SM20241

DOOR LATCH

1

6C

9ST12584-6

RIVET

6

9ST14882-2

DOOR BUMPER

2

9ST14882

DOOR BUMPER

2

6G

9SS27368-6

LOGO DECAL

1

6H

9SM22220

FAMILY NAME DECAL

1

7A

9SL12515-2

DOOR LATCH

1

9SS9225-64

SELF TAPPING SCREW

3

8A

9SL16909

Door Slide

1

9SS9225-64

SELF TAPPING SCREW

9

8C

9SS25719-3

EDGE GUARD

1

10

9SL12084

FUEL TROUGH

1

15

9SS12934-1

COVER SEAL

1

16

9SG8477

Decal Carrier

1

17

9SM21436

CARBON MONOXIDE WARNING DECAL

1

Covers Assembly

26

Big Red 500 - 12449

Printed 10/12/2015 at 11:52:38. Produced by Enigma.

Summary of Contents for BIG RED 500

Page 1: ...having Code Numbers 11585 11871 12449 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincoln...

Page 2: ...A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual s...

Page 3: ...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...

Page 4: ...m 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 s...

Page 5: ...nt 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 6 I Read and follow N...

Page 6: ...incoln Electric Wire Feeders A 7 ________________________________________________________________________________ Operation Section B Safety Instructions B 1 General Description B 1 Recommended Applic...

Page 7: ...Resetting Procedure D 5 ________________________________________________________________________ Troubleshooting Section E Safety Precautions E 1 How to Use Troubleshooting Guide E 1 Troubleshooting...

Page 8: ...F 40 C WELDER HEIGHT WIDTH DEPTH WEIGHT 36 87 2 in 28 28 in 65 1 in 936 5 mm 718 3 mm 1653 5 mm Welding Process DC Constant Current TIG OUTLETS 1 1 1 Output Range Amps 65A TO 500A 65A TO 250A Max Wel...

Page 9: ...tor s manual WARNING ANGLE OF OPERATION To achieve optimum engine performance the BIG RED 500 should be run in a level position The maximum angle of operation for the Deutz engine is 20 degrees in dir...

Page 10: ...e to metal bed or frame of vehicle Follow vehicle manufacture s instructions PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine Stop engine...

Page 11: ...he 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 cool...

Page 12: ...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 connec...

Page 13: ...D 500 is configured to allow for the addition of a Residual Current Device RCD to pro tect the 240V Single Phase Receptacle The auxiliary power area on the front panel of the BIG RED 500 has a hole si...

Page 14: ...gle 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...

Page 15: ...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 The BIG RED 500 is not recommended for pipe thawin...

Page 16: ...m minimum to maximum within each Range 1 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 an...

Page 17: ...n 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 11 OIL PRESSURE GAUGE An indicator of engine oil...

Page 18: ...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 ind...

Page 19: ...ring arc with best resistance to pop outs pre ferred for most welding To get this characteristic set the Output Range Selector to the lowest set ting that still provides the current you need and set t...

Page 20: ...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 1...

Page 21: ...ble length electrode diam eter 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 pow...

Page 22: ...00 10 0 0 0 0 1 PHASE 240V WATTS AMPS 3600 15 3600 15 2400 10 1200 5 0 0 0 0 BIG RED 500 Simultaneous Welding and Power Loads PLUS OR TABLE B 4 BIG RED 500 Extension Cord Length Recommendations Use th...

Page 23: ...ation 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 head shield work clamp elect...

Page 24: ...odical ly In particularly dirty locations this may be required once a week ENGINE MAINTENANCE Refer to the Periodic Checks section of the Engine Operator s Manual for the recommended maintenance sched...

Page 25: ...use To avoid personal injury do not bleed a hot engine This could cause fuel to spill onto a hot exhaust manifold creating a danger of fire Use motor oil designed for diesel engines that meets require...

Page 26: ...ry requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage t...

Page 27: ...e battery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manufacturer for proper charge...

Page 28: ...e equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The...

Page 29: ...E CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally...

Page 30: ...osition make sure the valve lever is in a vertical direction 3 Engine shut down solenoid not pulling in 4 On Off switch on for more than 60 sec before starting the On Off switch will need to be switch...

Page 31: ...cleaned replaced 2 Water in fuel 3 Fuel injector clogged or malfunc tioning 1 Fuel Shutdown solenoid not func tioning properly linkage binding 1 Faulty battery 2 Faulty engine alternator 3 Loose or b...

Page 32: ...F 1 DIAGRAMS F 1 BIG RED 500...

Page 33: ...F 2 DIAGRAMS F 2 BIG RED 500...

Page 34: ...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...

Page 35: ...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...

Page 36: ...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...

Page 37: ...ii THIS PAGE INTENTIONALLY LEFT BLANK...

Page 38: ...870 E Reactor Rectifier Fuel Tank Assembly AR 4 P 870 F Inner Control Panel Assembly AR 5 P 870 G Base Battery Lift Bale Asbly AR 6 P 870 H Engine Filter Assembly AR 7 P 870 J Generator Assembly AR 8...

Page 39: ...P 870 A jpg Index of Sub Assemblies 12449 2 Big Red 500 12449 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 40: ...2 6C 9SS17400 3 METRIC LOCKWASHER 2 6D 9SCF000102 8 32X 50BR RHS 2 6E 9ST9695 3 LOCKWASHER 2 6F 9SCF000103 8 32BR HN 4 8 9SG8477 Decal Carrier 1 9A 9SS31571 Meter Hole Cover 1 9B 9SS9225 65 THREAD FO...

Page 41: ...P 870 C jpg Case Front Control Panel Assembly 4 Big Red 500 12449 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 42: ...0 24 2 11D 9SS9225 63 THREAD FORMING SCREW CUTTING 2 11E 9SS9225 51 THREAD FORMING SCREW 4 12A 9SM20152 2 RECEPTACLE 115V 1 12B 9SS9225 63 THREAD FORMING SCREW CUTTING 4 13A 9SM20152 3 RECEPTACLE 230V...

Page 43: ...SS9225 63 THREAD FORMING SCREW CUTTING 2 21 9SG8477 Decal Carrier 1 22 9SG8477 Decal Carrier 1 9SS28115 MOUNTING STRAP ASSEMBLY 1 23A 9SS28114 MOUNTING STRAP 1 9ST11267 A INSULATOR 1 9ST11267 B INSULA...

Page 44: ...4HN 6 9SS24097 5 SHUNT LEAD ASBLY 1 9SS9262 1 PLAIN WASHER 1 9SE106A 15 LOCKWASHER 1 9SCF000021 1 2 13X1 00HHCS 1 9SCF000062 5 16 18X1 00HHCS 1 9SS9262 121 PLAIN WASHER 1 9SE106A 14 LOCKWASHER 1 9SCF0...

Page 45: ...P 870 D jpg Lower Control Panel Assembly 8 Big Red 500 12449 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 46: ...225 64 SELF TAPPING SCREW 1 9SS9225 64 SELF TAPPING SCREW 4 5A 9SG6560 REAR CONTROL BOX 1 5B 9ST11525 7 SPEED NUT 2 5C 9SS9225 64 SELF TAPPING SCREW 3 5D 9ST12380 1 BUSHING 2 7A 9SL15176 1 INNER CONTR...

Page 47: ...9SS9225 68 THREAD FORMING SCREW CUTTING 2 9SCF000413 1 4 20 X 1 00 HHCS 3 9SS9262 98 PLAIN WASHER 3 9SE106A 2 LOCKWASHER 3 9SCF000017 1 4 20HN 3 9SCF000412 1 4 20 X 50 HHCS 12 9ST9187 6 LOCKNUT 12 Rea...

Page 48: ...P 870 E jpg Reactor Rectifier Fuel Tank Assembly Big Red 500 12449 11 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 49: ...79 A INSULATING WASHER 2 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 1 6A 9ST13637 5 DIODE BRIDGE35A800VF W1 PH 4 6B 9SS10773 7 INSULATING WASHER 4 6C 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 4 7A 9SS13490...

Page 50: ...KEY PART NUMBER DESCRIPTION QTY 26 9SS14293 20 RELAY HEAVY DUTY 12VDC SPDT 1 Inner Control Panel Assembly Big Red 500 12449 13 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 51: ...P 870 F jpg Inner Control Panel Assembly 14 Big Red 500 12449 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 52: ...1 12C 9ST8833 24 HEX HD CAP SCREW 4 12D 9SE106A 15 LOCKWASHER 4 12E 9SCF000027 1 2 13HN 4 12F 9ST12380 1 BUSHING 2 12G 9ST13086 62 DECAL WARNING 1 9SE106A 15 LOCKWASHER 4 9SCF000027 1 2 13HN 4 12L 9S...

Page 53: ...27 31 CARRIAGE BOLT 2 15E 9ST9187 6 LOCKNUT 2 9SS9225 64 SELF TAPPING SCREW 3 9SS8070 49 BATTERY CABLE NEGATIVE 1 9SS8070 52 BATTERY CABLE POSITIVE 1 9SS20191 1 BATTERY TERMINAL COVER 1 20 9SS17851 DE...

Page 54: ...P 870 G jpg Base Battery Lift Bale Asbly Big Red 500 12449 17 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 55: ...1 PULLEY GUARD 1 9ST14731 31 METRIC HEX HD SCREW M8 X1 25 2 9SS9262 121 PLAIN WASHER 1 9ST11525 5 SPEED NUT1 4 20 1 9SS25930 6 TORX BUTTON HEAD SCREW 1 4 20X 62 1 9ST14731 13 METRIC HD SCREW M10 X 1 5...

Page 56: ...LOCKNUT 2 9ST14731 38 METRIC HEX HD SCREW M6 X1 0 2 9SS9262 98 PLAIN WASHER 2 9SS17400 3 METRIC LOCKWASHER 3 22A 9SM16980 OUTLET PIPE ELBOW 1 22B 9SS28113 CLAMP 2 EXHAUST PIPE 1 23A 9SS9262 56 PLAIN W...

Page 57: ...P 870 H jpg Engine Filter Assembly 20 Big Red 500 12449 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 58: ...COWLING 2 5B 9SS9225 64 SELF TAPPING SCREW 8 6A 9SM13641 5 EXCITER ROTOR ASBLY 1 6B 9SS20110 6 WASHER 1 9SE106A 3 LOCKWASHER 1 9ST8833 82 HEX HEAD CAP SCREW 1 7A 9SM21315 2 BRUSH HOLDER BRACKET ASBLY...

Page 59: ...SL15154 STATOR QUARTER BAFFLE 2 17B 9SL15154 1 STATOR QUARTER BAFFLE 2 9SS9225 64 SELF TAPPING SCREW 10 18A 9ST8833 62 HEX HD CAP SCREW 4 9SCF000112 3 8 16X1 75HHCS 2 18C 9SE106A 4 LOCKWASHER 6 19A 9S...

Page 60: ...P 870 J jpg Generator Assembly Big Red 500 12449 23 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 61: ...4A 9SM22157 AIR FILTER 1 4B 9SM22082 OUTPUT STUD COVER 1 4D 9SE106A 15 LOCKWASHER 2 4E 9SCF000344 HEX HD SCREW 2 5A 9SM22154 1 AIR BOX 1 5B 9ST9187 16 1 4 20 HLN 4 6 9SS9225 64 SELF TAPPING SCREW 2 9...

Page 62: ...P 870 K jpg Case Back Assembly Big Red 500 12449 25 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 63: ...APPING SCREW 8 9SS27368 6 LOGO DECAL 1 9SM22220 FAMILY NAME DECAL 1 9SL16911 Door Assembly 1 6A 9SL16910 Door Welded Assembly 1 6B 9SM20241 DOOR LATCH 1 6C 9ST12584 6 RIVET 6 9ST14882 2 DOOR BUMPER 2...

Page 64: ...NING 1 19 9ST13086 205 FUEL WARNING DECAL 1 9ST14882 1 DOOR BUMPER 2 21 9SM22257 CONNECTION LABEL 1 22 9SG8472 Wiring Diagram 1 23 9SS28039 1 DECAL GREEN INITIATIVE 1 Covers Assembly Big Red 500 12449...

Page 65: ...P 870 L jpg Covers Assembly 28 Big Red 500 12449 Printed 10 12 2015 at 11 52 38 Produced by Enigma...

Page 66: ...ive parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa mojada l Aislese del trabajo y de la tier...

Page 67: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de alimentaci...

Page 68: ...tomer 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...

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