Lincoln Global BIG RED 600 Operator'S Manual Download

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TROUBLESHOOTING

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Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Engine shuts down while under a
load.

Engine runs rough.

Engine will not shut off

Battery does not stay charged.

No welding output.

Welder has some/ no output and no
control. Auxiliary output OK

No auxiliary power.

1. High oil temperature.

1. Dirty fuel or air filters may need

cleaned/replaced.

2. Water in fuel.
3. Fuel injector clogged or malfunc-

tioning.

1. Fuel Shutdown solenoid not

functioning properly / linkage
binding.

1. Faulty battery .
2. Faulty engine alternator.
3. Loose or broken lead in charging

circuit.

4. Loose fan belt may need tighten-

ing.

1. Broken lead in weld rotor circuits.
2. Faulty field diode module.
3. Faulty weld rotor.
4. Open Breaker.
5. Check that selector switch is in

position.

1. Faulty remote kit.
2. Faulty output control Rheostat.
3. Faulty output control wiring.

1. Open breakers.
2. Faulty receptacle.
3. Faulty auxiliary circuit wiring.
4. GFCI tripped. (See Maintenance

Section)

5. Broken Lead in Auxiliary rotor cir-

cuit.

6. Faulty Auxiliary Rotor field Diode

module.

7. Faulty weld rotor.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Summary of Contents for BIG RED 600

Page 1: ... having Code Numbers 11599 11870 12448 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 lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future reference D...

Page 2: ...the general area IN 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 symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helm...

Page 3: ...ty 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 ...

Page 4: ...o 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 g...

Page 5: ... 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 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 CYLINDER M...

Page 6: ...lectric Wire Feeders A 7 ________________________________________________________________________________ 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 O...

Page 7: ...D 6 Cleaning D 6 Brush Removal and Replacement D 6 GFCI Testing and Resetting Procedure D 6 ________________________________________________________________________ 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...

Page 8: ... WELDER HEIGHT WIDTH DEPTH WEIGHT 36 87 2 in 28 28 in 65 1 in 916 5 mm 718 3 mm 1653 5 mm Welding Process DC Constant Current TIG OUTLETS 1 1 1 Output Range Amps 65A TO 600A 65A TO 250A Max Weld OCV Voltage 1800RPM 90 Volts 75 Volts Welding Output Current Voltage Duty 500A 40V 100 550A 34V 60 600A 30V 40 250A 20V 100 VOLTS 120 120 240 AMPS 20 15 15 Auxiliary Power 1 Single Phase 60 Hz AC PHYSICAL ...

Page 9: ... located to provide an unre stricted 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 can t be accidentally damaged from construction activ...

Page 10: ...ads for compo nents 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 instruc tions supplied with this machine Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up sp...

Page 11: ... 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 main tain proper cooling See the engine Owners Manual for procedures and frequency BATTERY CONNECTION GASES FROM BATTERY ca...

Page 12: ...ned 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 equip ment powered by this engine driven welder must a be grounded to the frame of the welder using a groundin...

Page 13: ... READY The BIG RED 600 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 600 has a 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 o...

Page 14: ...ngle 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 c...

Page 15: ...g 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 9 5 mm 3 8 diameter The BIG RED 600 is not recommended for pipe thawing GENERATOR The BIG RED 600 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 set...

Page 16: ... from 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 analog volt and amp meter kit available for easy installation into front panel See Accessory Section For K number BIG RED 600 CONTROLS AND SETTINGS All welder and engine controls are located on the ...

Page 17: ...en 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 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 ...

Page 18: ...hat 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 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 With a fully charged battery and the proper weight oil the engine should s...

Page 19: ...th 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 the Ouput 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 f...

Page 20: ... 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 2...

Page 21: ...able length electrode diameter wire feed speed contact tip to work dis tance 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 short ening the cont...

Page 22: ...1200 10 0 0 0 0 1 PHASE 240V WATTS AMPS 3600 15 3600 15 3600 15 2400 10 1200 5 0 0 0 0 BIG RED 600 Simultaneous Welding and Power Loads PLUS OR TABLE B 4 BIG RED 600 Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Current Amps 15 20 15 Voltage Volts 120 120 240 Load Watts 1800 2400 3600 30 60 9 18 40 30 75 12 9 23 75 50 150 23 15 ...

Page 23: ...nation 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 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 out put control on the welder Has a convenient twist lock ...

Page 24: ...eriodi cally 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 mainte nance schedule of the following a Engine Oil and Filter b Air Cleaner c Fuel Filter and Delivery System d Cooling Blower Belt e Battery f Cooling System Refer to Table D 1 at the end of this section for vari...

Page 25: ...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 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 dam...

Page 26: ...f any debris and rinse in diesel fuel 6 Re install the pre filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up Putting your fingers on the pull tabs push down evenly until the lower body of the pre filter screen contacts the floor of the upper cavity 7 Re insert the large white volume plug into the upper cavity 8 Place the O ring onto the angled ...

Page 27: ...8 7 Loosen the alternator mounting bolts and rotate the alternator towards the engine 8 Remove the old cooling blower belt and install a new one 9 Adjust the cold belt tension to 63 73 lbs midway between any two pulleys 10 Reinstall the air cleaner hose engine case side and end panel Reattach the negative battery cable Slide in and refasten the battery holder 11 Check the cooling blower belt tensi...

Page 28: ...ours MUFFLER MAY BE HOT ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER NAMEPLATES WARNING DECALS MAINTENANCE Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number ...

Page 29: ...he 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 circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI This will assure normal GFCI operation Plug a night light with an ON OFF switch or...

Page 30: ... may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING ...

Page 31: ...on 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 off and turned back on Defective CR3 Replace CR3 5 Fuel Filters dirty clogged gelled Colder Climates for gelled fuel remove and replace filters Run a diesel fuel treatment that dis solves the wax crystals...

Page 32: ...ned replaced 2 Water in fuel 3 Fuel injector clogged or malfunc tioning 1 Fuel Shutdown solenoid not functioning properly linkage binding 1 Faulty battery 2 Faulty engine alternator 3 Loose or broken lead in charging circuit 4 Loose fan belt may need tighten ing 1 Broken lead in weld rotor circuits 2 Faulty field diode module 3 Faulty weld rotor 4 Open Breaker 5 Check that selector switch is in po...

Page 33: ...F 1 DIAGRAMS F 1 BIG RED 600 ...

Page 34: ...F 2 DIAGRAMS F 2 ...

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 the Service Department for a replacement Give the equipment code number ...

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 the Service Department for a replacement Give the equipment code number ...

Page 37: ...F 5 DIAGRAMS F 5 BIG RED 600 ...

Page 38: ...ch electrically live parts or 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 Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 39: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de alimentación de poder de la máquina antes de ini ciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschal ten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Page 40: ...stomer 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 manufactur...

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