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E-1

TROUBLESHOOTING

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BIG RED™ 500

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

This  Troubleshooting  Guide  is  provided  to  help  you
locate  and  repair  possible  machine  malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look  under  the  column  labeled  “PROBLEM  (SYMP-
TOMS)”.    This  column  describes  possible  symptoms
that  the  machine  may  exhibit.    Find  the  listing  that
best  describes  the  symptom  that  the  machine  is
exhibiting. 

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE 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  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 GUIDE

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.

__________________________________________________________________________

WARNING

Содержание BIG RED 500

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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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