Lincoln Electric BIG RED 500 Service Manual
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Lincoln Electric BIG RED 500 Service Manual

Lincoln Electric BIG RED 500 Service Manual

Engine driven welder
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See also: Operator's Manual
RETURN TO MAIN MENU
SVM212-A
July, 2011
BIG RED
500/600
®
11585, 11599
For use with machine code number:
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.

SERVICE MANUAL

Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric BIG RED 500

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM212-A July, 2011 BIG RED 500/600 ® 11585, 11599 For use with machine code number: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety increased by proper installation .
  • Page 2 Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. 7.a. Use only compressed cylinders explosion. containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-vi Installation .
  • Page 7 NOTES BIG RED ® 500/600...
  • Page 8 NOTES THIS SECTION FOR BIG RED ® 500 ONLY. BIG RED ® 500/600...

  • Page 9: Table Of Contents

    Connection of Lincoln Electric Wire Feeders ........

  • Page 10: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - BIG RED ® (K2810-1) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder Idle 1890 125 cu. in 12VDC battery Fuel D2011L03i 32HP (24 kw) (2.05L) & Starter (20 US gal) Diesel Engine @ 1800 RPM Full Load 1800...

  • Page 11: Safety Precautions

    INSTALLATION SAFETY PRECAUTION ANGLE OF OPERATION Read this entire installation section before you start To achieve optimum engine performance the BIG installation. ® 500 should be run in a level position. The max- imum angle of operation for the Deutz engine is 20 WARNING degrees in direction of control panel angled up and 30 degrees for left, right and control panel angled down.

  • Page 12: Towing

    INSTALLATION TOWING PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- Use a recommended trailer for use with this equipment tions supplied with this machine. for road, in-plant and yard towing by a vehicle(1). If the user adapts a non-Lincoln trailer, he must assume WARNING responsibility that the method of attachment and usage does not result in a safety hazard or damage the weld-...

  • Page 13: Engine Break-In

    INSTALLATION ENGINE BREAK-IN BATTERY CONNECTION WARNING Lincoln Electric selects high quality, heavy-duty indus- 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.

  • Page 14: Muffler Outlet Pipe

    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...
  • Page 15 INSTALLATION RESIDUAL CURRENT DEVICE READY AUXILIARY POWER RECEPTACLES The BIG RED ® 500 is configured to allow for the addi- The auxiliary power of the BIG RED ® 500 consists of tion of a Residual Current Device (RCD) to protect the Single Phase 60Hz Power.
  • Page 16 NOTES BIG RED ® 500/600...
  • Page 17 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Instructions .

  • Page 18: Operation

    OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before The BIG RED 500 is a diesel engine driven welder, ® operating your BIG RED ® 500. offering reliable DC arc welding performance, with out- standing arc characteristics for all welding applications. The BIG RED ®...

  • Page 19: Controls And Settings

    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 2. OUTPUT CONTROL WELDING CONTROLS (Items 1-5) Provides fine adjustment of the current and open 1.

  • Page 20: Engine Controls

    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 the welding output at the control panel or remotely. 12. ENGINE PROTECTION For control at the control panel set the switch in the "LOCAL"...

  • Page 21: Engine Operation

    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 time Single-pole 20A rated. Provides overload protec- in cold weather. tion for the 120VAC (5-20R) NEMA Duplex Receptacle.

  • Page 22: Arc Gouging

    OPERATION WELDER OPERATION 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 DUTY CYCLE to get 175 amps. Duty Cycle is the percentage of time the load is being applied in a 10 minute period.
  • Page 23 OPERATION 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.
  • Page 24 A LINCOLN ELECTRIC WIRE FEEDER difficult to achieve required weld metal properties, or to achieve the required quality of welds needed to pass Lincoln Electric does NOT recommend constant nondestructive tests, when such welds are made current semiautomatic welding for applications under constant current operation.

  • Page 25: Auxiliary Power

    OPERATION AUXILIARY POWER: The auxiliary power is independent of the welding power and thus not effected by the weld control set- tings. 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.
  • Page 26 B-10 B-10 NOTES BIG RED ® 500/600...
  • Page 27 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Optional Features .
  • Page 28 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 pos- sible additional requirements.
  • Page 29 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Service Instructions .

  • Page 30: Maintenance

    MAINTENANCE BIG RED ® 500/600...

  • Page 31: Safety Precautions

    MAINTENANCE WEEKLY SAFETY PRECAUTIONS Blow out the machine with low pressure air periodical- ly. In particularly dirty locations, this may be required WARNING once a week. Have qualified personnel do the maintenance work. Turn the engine off before working inside ENGINE MAINTENANCE the machine.

  • Page 32: Oil Filter Change

    MAINTENANCE 3. Remove loose dirt from element with compressed Use motor oil designed for diesel engines that meets air or water hose directed from inside out. requirements service classification CC/CD/CE/CF/CF-4/CG-4 or CH-4. Compressed Air: 100 psi maximum with nozzles at least one inch away from ele- ACEA E1/E2/E3.

  • Page 33: Fuel Filters

    MAINTENANCE FUEL FILTERS BATTERY HANDLING GASES FROM BATTERY can explode. WARNING • Keep sparks, flame and cigarettes away from battery. To prevent EXPLOSION when: When working on the fuel system • INSTALLING A NEW BATTERY - discon- nect negative cable from old battery first •...

  • Page 34: Servicing Optional Spark Arrestor

    MAINTENANCE SERVICING OPTIONAL SPARK PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug. ARRESTOR Clean every 100 hours. CHARGING THE BATTERY When you charge, jump, replace, or otherwise connect WARNING battery cables to the battery, be sure the polarity is cor- •...

  • Page 35: Welder / Generator Maintenance

    MAINTENANCE WELDER / GENERATOR MAINTE- NANCE 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 par- ticularly dirty areas. BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly.
  • Page 36 MAINTENANCE FIGURE D.2 - MAJOR COMPONENT LOCATIONS 1. Case Front & Control Panel Assembly 2. Lower Control Panel Assembly 3. Reactor, Rectifier & Fuel Tank Assembly 4. Inner Control Panel Assembly 5. Base, Battery & Lift Bale Assembly 6. Engine & Filter Assembly 7.
  • Page 37 NOTES BIG RED ® 500/600...
  • Page 38 NOTES THIS SECTION FOR BIG RED ® 600 ONLY. BIG RED ® 500/600...

  • Page 39: A-1 Table Of Contents - Installation Section

    Connection of Lincoln Electric Wire Feeders ........

  • Page 40: Installation

    AA-2 AA-2 INSTALLATION TECHNICAL SPECIFICATIONS - BIG RED ® (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...

  • Page 41: Safety Precautions

    AA-3 AA-3 INSTALLATION SAFETY PRECAUTION ANGLE OF OPERATION Read this entire installation section before you start To achieve optimum engine performance the BIG installation. ® 600 should be run in a level position. The max- imum angle of operation for the Deutz engine is 30 WARNING degrees fore and aft, 40 degrees right and 45 degrees left.

  • Page 42: Towing

    AA-4 AA-4 INSTALLATION TOWING PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc- Use a recommended trailer for use with this equipment tions supplied with this machine. for road, in-plant and yard towing by a vehicle(1). If the user adapts a non-Lincoln trailer, he must assume WARNING responsibility that the method of attachment and usage does not result in a safety hazard or damage the weld-...

  • Page 43: Engine Break-In

    INSTALLATION BATTERY CONNECTION ENGINE BREAK-IN WARNING Lincoln Electric selects high quality, heavy-duty indus- 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.

  • Page 44: Muffler Outlet Pipe

    AA-6 AA-6 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...
  • Page 45 AA-7 AA-7 INSTALLATION RESIDUAL CURRENT DEVICE READY AUXILIARY POWER RECEPTACLES The BIG RED ® 600 is configured to allow for the addi- The auxiliary power of the BIG RED ® 600 consists of tion of a Residual Current Device (RCD) to protect the Single Phase 60Hz Power.

  • Page 46: Connection Of Lincoln Electric Wire Feeders

    ® ® ------------------------------------------------------------------------ out an internal contactor, and LN-25 ® PRO may be Lincoln Electric does NOT recommend constant used with the BIG RED ® 600. current semiautomatic welding for applications which need to meet specified weld metal chemical 1. Shut the welder off.
  • Page 47 BB-1 BB-1 TABLE OF CONTENTS - OPERATION SECTION Operation ................BB-1 Safety Instructions .

  • Page 48: Operation

    BB-2 BB-2 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 out- standing arc characteristics for all welding applications. The BIG RED ®...

  • Page 49: Controls And Settings

    BB-3 BB-3 OPERATION CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure BB.1 and the explanations that follow. Figure BB.1 Case Front Panel Controls 2. OUTPUT CONTROL WELDING CONTROLS (Items 1-5) Provides fine adjustment of the current and open 1.

  • Page 50: Engine Controls

    BB-4 BB-4 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.

  • Page 51: Engine Operation

    BB-5 BB-5 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 time Single-pole 20A rated. Provides overload protec- in cold weather. tion for the 120VAC (5-20R) NEMA Duplex Receptacle.

  • Page 52: Arc Gouging

    BB-6 BB-6 OPERATION WELDER OPERATION 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 DUTY CYCLE to get 175 amps. Duty Cycle is the percentage of time the load is being applied in a 10 minute period.
  • Page 53 BB-7 BB-7 OPERATION The BIG RED ® 600 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.
  • Page 54 A LINCOLN ELECTRIC WIRE FEEDER difficult to achieve required weld metal properties, or to achieve the required quality of welds needed to pass Lincoln Electric does NOT recommend constant nondestructive tests, when such welds are made current semiautomatic welding for applications under constant current operation.

  • Page 55: Auxiliary Power

    BB-9 BB-9 OPERATION AUXILIARY POWER: The auxiliary power is independent of the welding power and thus not effected by the weld control set- tings. 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 BB.4.
  • Page 56 BB-10 BB-10 NOTES BIG RED ® 500/600...
  • Page 57 CC-1 CC-1 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................CC-1 Optional Features .
  • Page 58 CC-2 CC-2 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 pos- sible additional requirements.
  • Page 59 DD-1 DD-1 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................DD-1 Service Instructions .

  • Page 60: Maintenance

    DD-2 DD-2 MAINTENANCE BIG RED ® 500/600...

  • Page 61: Safety Precautions

    DD-3 DD-3 MAINTENANCE WEEKLY SAFETY PRECAUTIONS Blow out the machine with low pressure air periodical- ly. In particularly dirty locations, this may be required WARNING once a week. Have qualified personnel do the maintenance work. Turn the engine off before working inside ENGINE MAINTENANCE the machine.

  • Page 62: Oil Filter Change

    DD-4 DD-4 MAINTENANCE Use motor oil designed for diesel engines that meets 3. Remove loose dirt from element with compressed requirements service classification air or water hose directed from inside out. CC/CD/CE/CF/CF-4/CG-4 or CH-4. Compressed Air: 100 psi maximum with nozzles at least one inch away from ele- ACEA E1/E2/E3.

  • Page 63: Fuel Filters

    DD-5 DD-5 MAINTENANCE FUEL FILTERS 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, WARNING push down evenly until the lower body of the pre-fil- ter screen contacts the floor of the upper cavity.

  • Page 64: Secondary Fuel Filter

    DD-6 DD-6 MAINTENANCE BATTERY HANDLING 5. Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop GASES FROM BATTERY can explode. is heard. If you do not hear the click you have not •...

  • Page 65: Nameplates / Warning Decals

    DD-7 DD-7 MAINTENANCE SERVICING OPTIONAL SPARK PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug. ARRESTOR Clean every 100 hours. CHARGING THE BATTERY When you charge, jump, replace, or otherwise connect WARNING battery cables to the battery, be sure the polarity is cor- •...

  • Page 66: Welder / Generator Maintenance

    DD-8 DD-8 MAINTENANCE WELDER / GENERATOR MAINTE- NANCE STORAGE Store the BIG RED ® 600 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 par- ticularly dirty areas.
  • Page 67 DD-9 DD-9 MAINTENANCE FIGURE DD.2 - MAJOR COMPONENT LOCATIONS 1. Case Front & Control Panel Assembly 2. Lower Control Panel Assembly 3. Reactor, Rectifier & Fuel Tank Assembly 4. Inner Control Panel Assembly 5. Base, Battery & Lift Bale Assembly 6.
  • Page 68 NOTES UNLESS NOTED OTHERWISE THE FOLLOWING SECTIONS ARE FOR THE SERVICING AND REPAIR OF THE BIG RED ® 500 AND THE BIG RED ® 600. BIG RED ® 500/600...
  • Page 69 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 70: Theory Of Operation

    RELAY 12 VDC GENERAL DESCRIPTION The BIG RED 500 and 600 machines are diesel engine driven welders capable of producing DC constant cur- rent output for stick welding, arc gouging, and DC TIG welding. They are also capable of producing 6000 watts of auxiliary power via an independent auxiliary rotor and stator.
  • Page 71 THEORY OF OPERATION FIGURE E.2 - BATTERY, RUN/STOP SWITCH, STARTER, ENGINE ALTERNATOR, AND ENGINE SHUTDOWN CIRCUITS THREE PHASE RECTIFIER TAPPED HOT START REACTOR RELAY START CIRCUIT FUEL TEMP. PRESSURE PART OF SENSOR SELECTOR SENSOR SENSOR AND STICK/TIG SWITCH GAUGE SWITCH GAUGE GAUGE AUXILIARY...
  • Page 72 THEORY OF OPERATION FIGURE E.3 - AUXILIARY ROTOR, AUXILIARY STATOR AND EXCITATION (FLASHING) THREE PHASE RECTIFIER TAPPED HOT START REACTOR RELAY START CIRCUIT FUEL TEMP. PRESSURE PART OF SENSOR SELECTOR SENSOR SENSOR AND STICK/TIG SWITCH GAUGE SWITCH GAUGE GAUGE AUXILIARY 65 VAC STATOR 65 VAC...
  • Page 73 THEORY OF OPERATION FIGURE E.4 - WELD ROTOR, WELD STATOR, SELECTOR SWITCH AND FIELD CIRCUIT THREE PHASE RECTIFIER TAPPED HOT START REACTOR RELAY START CIRCUIT FUEL TEMP. PRESSURE PART OF SENSOR SELECTOR SENSOR SENSOR AND STICK/TIG SWITCH GAUGE SWITCH GAUGE GAUGE AUXILIARY 65 VAC...
  • Page 74 Tapped Reactor through the Selector Switch. Dependent on the Selector Switch setting the Tapped Reactor provides four (Big Red 500) or five (Big Red 600) overlapping output current settings. The more reactor windings that are in the welding circuit the lower the output current.
  • Page 75 THEORY OF OPERATION ENGINE PROTECTION: BATTERY CIRCUIT: There is a warning indicator light for engine high oil The battery circuit breaker protects the engine circuitry temperature or low oil pressure. The light remains off that powers the three gauges, fuel/hours, oil tempera- with proper oil temperature and proper oil pressure.
  • Page 76 NOTES BIG RED ® 500/600...
  • Page 77 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 78: Troubleshooting And Repair

    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.
  • Page 79 See the Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. BIG RED ®...
  • Page 80 Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. BIG RED ®...
  • Page 81 Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. BIG RED ®...
  • Page 82 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. BIG RED ®...
  • Page 83 “crank” but will not start. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. BIG RED ®...
  • Page 84 3. The battery may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. BIG RED ®...
  • Page 85 #206 to #207. See the Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. BIG RED ®...
  • Page 86 F-10 F-10 NOTES BIG RED ® 500/600...

  • Page 87: Engine Alternator Test

    (BIG RED 500 ONLY) (DEUTZ 2011L03i) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 88 F-12 F-12 TROUBLESHOOTING AND REPAIR ENGINE ALTERNATOR TEST (BIG RED 500 ONLY) (DEUTZ 2011L03i) (continued) FIGURE F.1 – ENGINE ACCESS DOOR ENGINE ACCESS DOOR PROCEDURE WARNING 1. Turn the engine off. ELECTRIC SHOCK can kill. 2. Open and remove engine access door. See •...
  • Page 89 F-13 F-13 TROUBLESHOOTING AND REPAIR ENGINE ALTERNATOR TEST (BIG RED 500 ONLY) (DEUTZ 2011L03i) (continued) FIGURE F.2 – ENGINE SIDE PANEL ENGINE SIDE PANEL MACHINE REAR RIGHT SIDE MACHINE VIEW ENGINE SIDE PANEL MOUNTING BOLTS 10. Carefully check from leads 238 to 5F and 239 to 5F.
  • Page 90 F-14 F-14 NOTES BIG RED ® 500/600...

  • Page 91: Output Rectifier Test

    OUTPUT RECTIFIER TEST (3 PHASE) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 92 F-16 F-16 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST (3 PHASE) (continued) FIGURE F.3 – OUTPUT RECTIFIER LOCATION OUTPUT RECTIFIER PROCEDURE 1. Turn the engine off. 7. Using an ohmmeter or diode tester, check the Output Rectifier. See Table F.1. 2. Perform the Case Cover Removal Procedure, NOTE: An individual open diode will not be as needed.
  • Page 93 F-17 F-17 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST (3 PHASE) (continued) FIGURE F.4 – OUTPUT RECTIFIER TERMINAL LOCATIONS TERMINAL TERMINAL TERMINAL POSITIVE DC (+) NEGATIVE BYPASS FILTER DC (-) ASSEMBLY LEAD BIG RED ® 500/600...
  • Page 94 F-18 F-18 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST (3 PHASE) (continued) TABLE F.1 – DIODE TEST TABLE DIODE TEST TEST INSTRUMENT DIODE BIAS & EXPECTED (+) Lead (-) Lead TEST RESULT Forward Bias Terminal A1 DC(+) (Low Resistance) Forward Bias Terminal B1 DC(+) (Low Resistance)

  • Page 95: Engine Protection Relay Test

    ENGINE PROTECTION RELAY TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 96 F-20 F-20 TROUBLESHOOTING AND REPAIR ENGINE PROTECTION RELAY TEST (continued) FIGURE F.5 – ENGINE PROTECTION RELAY LOCATION ENGINE PROTECTION RELAY PROCEDURE 1. Turn the engine off. 5. Using an ohmmeter, perform the tests in Table F.2. See Figure F.6. 2. Perform the Case Cover Removal Procedure, as necessary.
  • Page 97 F-21 F-21 TROUBLESHOOTING AND REPAIR ENGINE PROTECTION RELAY TEST (continued) FIGURE F.6 – TEST POINTS TABLE F.2 – ENGINE PROTECTION RELAY TESTING TEST CONDITIONS TERMINAL TERMINAL EXPECTED READING NO VOLTAGE APPLIED 0 OHMS NO VOLTAGE APPLIED INFINITE RESISTANCE NO VOLTAGE APPLIED 86 (+) 85 (-) 80 - 90 OHMS...
  • Page 98 F-22 F-22 NOTES BIG RED ® 500/600...

  • Page 99: Weld Stator Voltage Test

    WELD STATOR VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 100 F-24 F-24 TROUBLESHOOTING AND REPAIR WELD STATOR VOLTAGE TEST (continued) FIGURE F.7 – OUTPUT RANGE SELECTOR SWITCH LOCATION CURRENT RANGE SELECTOR SWITCH PROCEDURE 1. Turn the engine off. 5. Start the engine 2. Perform the Case Cover Removal Procedure, 6. Check for approx. 55VAC from leads W1/W6 to as necessary.
  • Page 101 F-25 F-25 TROUBLESHOOTING AND REPAIR WELD STATOR VOLTAGE TEST (continued) FIGURE F.8 – SELECTOR SWITCH LEAD LOCATIONS W5 AND W4 W2 AND W3 W1 AND W6 10. Check the resistances from phase to phase. The resistance should be very low. See Wiring Diagram.
  • Page 102 F-26 F-26 NOTES BIG RED ® 500/600...

  • Page 103: Auxiliary Rotor Voltage And Resistance Test

    AUXILIARY ROTOR VOLTAGE AND RESISTANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 104 F-28 F-28 TROUBLESHOOTING AND REPAIR AUXILIARY ROTOR VOLTAGE AND RESISTANCE TEST (continued) FIGURE F.9 – AUXILIARY ROTOR BRUSH TERMINAL LOCATION AUXILIARY ROTOR BRUSH TERMINALS MACHINE FRONT RIGHT SIDE VIEW WELD ROTOR BRUSH ACCESS PLATE PROCEDURE 1. Turn the engine off. 5.
  • Page 105 F-29 F-29 TROUBLESHOOTING AND REPAIR AUXILIARY ROTOR VOLTAGE AND RESISTANCE TEST (continued) FIGURE F.10 – LEADS 202(-) AND 204(+) AUXILIARY ROTOR 202(-) 204(+) BRUSH TERMINALS MACHINE FRONT RIGHT SIDE VIEW WELD ROTOR BRUSH ACCESS PLATE AUXILIARY ROTOR RESISTANCE CHECK: 7. To check the rotor resistance, perform the Case 11.
  • Page 106 F-30 F-30 NOTES BIG RED ® 500/600...

  • Page 107: Weld Rotor Resistance Test

    WELD ROTOR RESISTANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 108 F-32 F-32 TROUBLESHOOTING AND REPAIR WELD ROTOR RESISTANCE TEST (continued) FIGURE F.11 – WELD ROTOR BRUSH ACCESS PLATE LOCATION WELD ROTOR BRUSH ACCESS PLATE WELD ROTOR BRUSH ACCESS PLATE BOLTS MACHINE FRONT RIGHT SIDE VIEW PROCEDURE 1. Turn the engine off. 8.
  • Page 109 F-33 F-33 TROUBLESHOOTING AND REPAIR WELD ROTOR RESISTANCE TEST (continued) FIGURE F.12 – LEADS 201A AND 200A(+) 201A 200B(+) WELD ROTOR BRUSH TERMINALS MACHINE FRONT RIGHT SIDE VIEW BIG RED ® 500/600...

  • Page 110: Ocv Stick Mode

    F-34 F-34 TROUBLESHOOTING AND REPAIR OCV STICK MODE WELD OUTPUT VOLTAGE WAVEFORM FINE CURRENT CONTROL AT MAXIMUM 50V/Div 0 volts 5ms/DIv This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 111: Ocv Tig Mode

    F-35 F-35 TROUBLESHOOTING AND REPAIR OCV TIG MODE FINE CURRENT CONTROL AT MAXIMUM 0 volts 50V/Div 5ms/DIv This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 112: Normal Ocv Waveform

    F-36 F-36 TROUBLESHOOTING AND REPAIR NORMAL OCV WAVEFORM 120 VAC SUPPLY (NO LOAD) 50V/Div 0 volts 5ms/DIv This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 113 F-37 F-37 TROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT WAVEFORM 240 VAC SUPPLY (NO LOAD) 0 volts 100V/Div 5ms/DIv This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 100 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 114 F-38 F-38 NOTES BIG RED ® 500/600...

  • Page 115: Case Cover Removal And Replacement

    CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 116 F-40 F-40 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – CASE COVER LOCATIONS RIGHT SIDE VIEW DOOR SLIDE ROOF GAS CAP DOOR ASSEMBLY RIGHT CASE SIDE PROCEDURE 1. Open door. See Figure F.13. 9. Using 1/2” wrench, remove four mounting screws from left rear case side.
  • Page 117 F-41 F-41 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.14 – CASE COVER LOCATIONS LEFT SIDE VIEW LEFT REAR CASE SIDE LEFT FRONT CASE SIDE REPLACEMENT PROCEDURE 1. Using a 1/2” wrench, replace four mounting bolts on the left rear case side. 2.
  • Page 118 F-42 F-42 NOTES BIG RED ® 500/600...

  • Page 119: Current Range Switch Removal And Replacement

    CURRENT RANGE SWITCH REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 120 F-44 F-44 TROUBLESHOOTING AND REPAIR CURRENT RANGE SWITCH REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – CURRENT RANGE SELECTOR SWITCH LOCATION CURRENT RANGE SELECTOR SWITCH PROCEDURE 1. Turn machine off. 7. Using a 3/8” wrench, remove the three Current Range Switch mounting screws. One is locat- 2.
  • Page 121 F-45 F-45 TROUBLESHOOTING AND REPAIR CURRENT RANGE SWITCH REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – CURRENT RANGE SELECTOR SWITCH HANDLE LOCATION CURRENT RANGE ALLEN BOLT SWITCH HANDLE DRIFT PIN MACHINE FRONT PANEL FIGURE F.17 – CURRENT RANGE SELECTOR SWITCH LEAD LOCATIONS W2/W3 W1/W6 A6/A6A...
  • Page 122 F-46 F-46 TROUBLESHOOTING AND REPAIR CURRENT RANGE SWITCH REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – CURRENT RANGE SWITCH MOUNTING SCREWS CURRENT RANGE SELECTOR SWITCH MOUNTING SCREW (LOCATED ON MACHINE FRONT PANEL) CURRENT RANGE SELECTOR SWITCH MOUNTING SCREWS REPLACEMENT PROCEDURE 1. Position the new Current Range Switch into its proper location.

  • Page 123: Output Rectifier Bridge Removal And Replacement

    OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 124 F-48 F-48 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.19 – OUTPUT RECTIFIER LOCATION OUTPUT RECTIFIER PROCEDURE 1. Turn machine off. 2. Perform the Case Cover Removal Procedure. 3. Locate the Output Rectifier Bridge. See Figure F.19.
  • Page 125 F-49 F-49 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.20 – OUTPUT RECTIFIER TERMINAL LOCATIONS TERMINAL TERMINAL TERMINAL NEGATIVE POSITIVE DC (-) DC (+) FIGURE F.21 – OUTPUT RECTIFIER MOUNTING SCREWS MOUNTING SCREWS MOUNTING SCREWS MOUNTING SCREWS BIG RED ®...
  • Page 126 F-50 F-50 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Apply a thin coating of Dow Corning 340 to all electrical connection points. 2. Carefully maneuver the new Output Rectifier into its proper location. 3. Secure the Output Rectifier using the seven previously removed mounting screws.

  • Page 127: Welder Separation Procedure

    WELDER SEPARATION PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 128 F-52 F-52 TROUBLESHOOTING AND REPAIR WELDER SEPARATION PROCEDURE (continued) FIGURE F.22 – AUXILIARY ROTOR LOCATION AUXILIARY ROTOR PROCEDURE 1. Turn machine off. 7. Using pliers, disconnect the fuel return line. See Figure F.23. 2. Perform the Case Cover Removal Procedure. 8.
  • Page 129 F-53 F-53 TROUBLESHOOTING AND REPAIR WELDER SEPARATION PROCEDURE (continued) FIGURE F.23 – FUEL STOP VALVE, FUEL RETURN LINE, LEADS 226 & 5F FUEL RETURN LINE TO ENGINE TO FUEL TANK HOSE CLAMPS MACHINE REAR RIGHT SIDE MACHINE VIEW FUEL STOP 226 &...
  • Page 130 F-54 F-54 TROUBLESHOOTING AND REPAIR WELDER SEPARATION PROCEDURE (continued) FIGURE F.24 – ENGINE SIDE COVER BOLTS & LEADS 5F & 239 ENGINE SIDE PANEL MACHINE REAR RIGHT SIDE MACHINE VIEW ENGINE SIDE PANEL MOUNTING BOLTS 21. Disconnect leads 201 & 200B from the weld 28.
  • Page 131 F-55 F-55 TROUBLESHOOTING AND REPAIR WELDER SEPARATION PROCEDURE (continued) FIGURE F.25 – OUTPUT CURRENT RANGE SWITCH CONNECTIONS W5 AND W4 W2 AND W3 W1 AND W6 FIGURE F.26 – LEAD 5 FROM GROUND STUD GROUND STUD (BEHIND FRONT PANEL) BIG RED ®...
  • Page 132 F-56 F-56 TROUBLESHOOTING AND REPAIR WELDER SEPARATION PROCEDURE (continued) FIGURE F.27 – LEADS 202(-) & 204(+) AUXILIARY ROTOR 202(-) 204(+) BRUSH TERMINALS MACHINE FRONT RIGHT SIDE VIEW WELD ROTOR BRUSH ACCESS PLATE FIGURE F.28 – LEADS 201 & 200B 201A 200B(+) WELD ROTOR BRUSH TERMINALS...
  • Page 133 F-57 F-57 TROUBLESHOOTING AND REPAIR WELDER SEPARATION PROCEDURE (continued) FIGURE F.29 – HORIZONTAL SHELF MOUNTING BOLT LOCATIONS HORIZONTAL SHELF MOUNTING BOLTS MACHINE RIGHT SIDE FIGURE F.30 – BASE ASSEMBLY MOUNTING BOLT LOCATIONS RIGHT SIDE MACHINE VIEW CENTER MOUNTING BOLT (BEHIND FRONT PANEL) LIFT FRAME / BASE ASSEMBLY MOUNTING BOLTS FRONT PANEL / HORIZONTAL SUPPORT RAIL...
  • Page 134 F-58 F-58 TROUBLESHOOTING AND REPAIR WELDER SEPARATION PROCEDURE (continued) REPLACEMENT PROCEDURE 13. Connect leads 3 and 6 to circuit breaker CB4. WARNING See Wiring Diagram. • Lift only with equipment of 14. Connect lead 602C from diode bridge D3. See adequate lifting capacity.

  • Page 135: Auxiliary Stator Removal And Replacement

    AUXILIARY STATOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 136 F-60 F-60 TROUBLESHOOTING AND REPAIR AUXILIARY STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.31 – EXCITOR STATOR LOCATION AUXILIARY STATOR MACHINE RIGHT SIDE VIEW MACHINE FRONT PROCEDURE 1. Turn machine off. 2. Perform the Case Cover Removal Procedure. 3. Perform the Welder Separation Procedure. 4.
  • Page 137 F-61 F-61 TROUBLESHOOTING AND REPAIR AUXILIARY STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.32 – STATOR COWLING BOLT LOCATIONS STATOR COWLING MACHINE RIGHT SIDE VIEW MACHINE FRONT STATOR COWLING BOLTS (8) FIGURE F.33 – BRUSH HOLDER ASSEMBLY REMOVAL BRUSH HOLDER ASSEMBLY BRUSH HOLDER ASSEMBLY SCREWS BIG RED...
  • Page 138 F-62 F-62 TROUBLESHOOTING AND REPAIR AUXILIARY STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.34 – THRU BOLT LOCATION THRU BOLTS REPLACEMENT PROCEDURE 1. Replace Auxiliary Stator. 2. Using a 1/2” wrench, tighten the four thru bolts securing the Auxiliary Stator to the main stator to fourteen foot pounds.

  • Page 139: Auxiliary Rotor Removal And Replacement

    AUXILIARY ROTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 140 F-64 F-64 TROUBLESHOOTING AND REPAIR AUXILIARY ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.35 – EXCITOR ROTOR AND THRU BOLT LOCATION GENTLY PRY HERE ROTOR THRU BOLT AUXILIARY ROTOR PROCEDURE 1. Turn machine off. 7. Carefully remove the Auxiliary Rotor from the tapered shaft of the weld rotor, by applying even 2.
  • Page 141 F-65 F-65 TROUBLESHOOTING AND REPAIR AUXILIARY ROTOR REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Replace Auxiliary Rotor. 2. Replace the thru bolt securing the auxiliary rotor to the weld rotor. Hand tighten only. 3. Carefully place the Auxiliary Rotor on to the tapered shaft of the weld rotor.
  • Page 142 F-66 F-66 NOTES BIG RED ® 500/600...

  • Page 143: Weld Stator Removal And Replacement

    WELD STATOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 144 F-68 F-68 TROUBLESHOOTING AND REPAIR WELD STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.36 – WELD STATOR LOCATION WELD MACHINE ROTOR RIGHT SIDE WELD STATOR PROCEDURE 1. Turn machine off. 8. Using a 3/4” wrench, remove the Weld Stator mounting bolts from the feet of the Weld Stator 2.
  • Page 145 F-69 F-69 TROUBLESHOOTING AND REPAIR WELD STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.37 – LEFT AND RIGHT BAFFLE MOUNTING SCREW LOCATIONS LEFT BAFFLE MACHINE RIGHT SIDE RIGHT BAFFLE MOUNTING SCREWS 11. Using a hoist and lifting straps, elevate the 16. Using a 9/16” wrench, remove the six bolts Weld Stator frame about one inch off of the securing the Weld Stator assembly to the Weld Stator mountings.
  • Page 146 F-70 F-70 TROUBLESHOOTING AND REPAIR WELD STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.38 – STATOR MOUNTING BOLT LOCATIONS STATOR COWLINGS WELD STATOR MACHINE RIGHT SIDE COWLING MOUNTING MOUNTING BOLTS BOLTS FIGURE F.39 – WELD STATOR BRUSH HOLDER AND STATOR ASSEMBLY MOUNTING BOLTS LIFTING STRAPS MACHINE RIGHT SIDE...
  • Page 147 F-71 F-71 TROUBLESHOOTING AND REPAIR WELD STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.40 – WELD STATOR BRUSH HOLDER AND STATOR ASSEMBLY MOUNTING BOLTS STATOR ASSEMBLY MOUNTING BOLTS WELD STATOR WELD STATOR BRUSH HOLDER BIG RED ® 500/600...
  • Page 148 F-72 F-72 TROUBLESHOOTING AND REPAIR WELD STATOR REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Adjust height on hoist so that the Weld Stator 10. Using a 3/4” wrench, install the Weld Stator can be carefully and gently maneuvered into mounting bolts to the feet of the Weld Stator machine.

  • Page 149: Weld Rotor Removal And Replacement

    WELD ROTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 150 F-74 F-74 TROUBLESHOOTING AND REPAIR WELD ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.41 – WELD ROTOR LOCATION WELD ROTOR MACHINE RIGHT SIDE PROCEDURE 1. Turn machine off. 9. Using an 17mm wrench, remove the eight bolts securing the blower paddles to the engine fly- 2.
  • Page 151 F-75 F-75 TROUBLESHOOTING AND REPAIR WELD ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.42 – LIFTING STRAP POINTS MACHINE RIGHT SIDE LIFTING STRAPS WELD ROTOR FIGURE F.43 – BLOWER PADDLE LOCATION MACHINE REAR BLOWER PADDLES MOUNTING BOLTS RIGHT SIDE MACHINE VIEW BLOWER PADDLES BIG RED ®...
  • Page 152 F-76 F-76 TROUBLESHOOTING AND REPAIR WELD ROTOR REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Replace the weld rotor and flexplate assembly to the machine. 2. Using a 17mm wrench, replace the eight bolts securing the blower paddles to the engine fly- wheel.

  • Page 153: Retest After Repair

    OR • If any electrical components are repaired or replaced. ENGINE OUTPUT MODEL / ENGINE NO LOAD RPM LOAD RPM Big Red 500 / Deutz 1890 1800 D2011Lo3i Big Red 600 / Deutz FL3 912 1890...
  • Page 154 F-78 F-78 NOTES BIG RED ® 500/600...
  • Page 155 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - BIG RED ®...

  • Page 156: Electrical Diagrams

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - BIG RED ® 500 CODE 11599 (G6668) BIG RED 500 (K2810-1) WIRING DIAGRAM W2/W3 W1/W6 SEE SELECTOR SWITCH CONNECTION DETAIL C2, B2, & A2 LEADS ARE NOT USED AMMETER A6/A6A (OPTIONAL) AUXILIARY STATOR WELD STATOR...
  • Page 157 ELECTRICAL DIAGRAMS SCHEMATIC - BIG RED ® 500 CODE 11599 (G6822) ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: INPUT SIGNAL K2861-1 REMOTE CONTROL (Optional) 100 ft. Cable PLUG FOR REMOTE 4.5V CONTROL POTENTIOMETER B = BLACK SELECTOR SWITCH/COARSE CURRENT CONTROL G = GREEN Tap 1: 65 - 115 Tap 2: 105 -220 W = WHITE...
  • Page 158 ELECTRICAL DIAGRAMS WIRING DIAGRAM - BIG RED ® 600 CODE 11585 (G6574) BIG RED 600 (K2811-1) WIRING DIAGRAM W2/W3 W1/W6 SEE SELECTOR SWITCH CONNECTION DETAIL AMMETER (OPTIONAL) AUXILIARY STATOR WELD STATOR WINDINGS VOLTMETER (OPTIONAL) 240V/15A 120V/16A 1 PHASE 1 PHASE 222A (BLUE) (YELLOW)
  • Page 159 ELECTRICAL DIAGRAMS SCHEMATIC - BIG RED ® 600 CODE 11585 (G6791) ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: INPUT SIGNAL K2861-1 REMOTE CONTROL (Optional) 100 ft. Cable PLUG FOR REMOTE 4.5V CONTROL POTENTIOMETER SELECTOR SWITCH/COARSE CURRENT CONTROL B = BLACK G = GREEN Tap 1: 65 - 115 W = WHITE Tap 2: 105 -220...

This manual is also suitable for:

Big red 600

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