Lincoln Electric BIG RED 500 Service Manual page 134

F-58
WELDER SEPARATION PROCEDURE (continued)
REPLACEMENT PROCEDURE
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
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1. Clear any obstructions and prepare for front
end replacement to machine.
2. Using hoisting straps, carefully position the
front half of the welder. Against the engine sta-
tor assembly.
3. Using a 3/4" wrench, replace the four bolts
securing the lift frame assembly to the base
assembly.
4. Using a 7/16" wrench, replace the nut and
washer at the center locating bolt to the inside
lower center of the case front assembly.
5. Using a 1/2" wrench, replace the two bolts
securing the case front to the horizontal support
rails.
6. Using a 1/2" wrench, replace the four bolts
securing the front panel assembly to the base
assembly.
7. Using a 1/2" wrench, replace the two bolts (left
and right) securing the horizontal shelf to the
left and right vertical baffle assemblies.
8. Connect lead 222 to the hot start choke. See
Wiring Diagram.
9. Connect leads 206A & 221 to diode bridge D4.
See Wiring Diagram.
10. Connect leads 201 & 200B to the weld rotor
brushes. See Wiring Diagram.
11. Connect leads 202 & 204 to the auxiliary rotor
brushes.
12. Connect lead 5 to the ground stud on the back
of casefront.
TROUBLESHOOTING AND REPAIR
BIG RED
13. Connect leads 3 and 6 to circuit breaker CB4.
See Wiring Diagram.
14. Connect lead 602C from diode bridge D3. See
Wiring Diagram.
15. Connect lead 203A to circuit breaker CB6. See
Wiring Diagram.
16. Connect leads 207 to diode D4 and lead 206 to
the Stick/Tig switch. See Wiring Diagram.
17. Install any necessary cable ties.
18. Using a 7/16" wrench, connect leads W1/W6,
W4/W5, W2/W3 to the output current range
switch.
19. Connect leads 228 & 235 to the oil pressure
sensor. See Wiring Diagram.
20. Connect leads 241, 235A & 234 to the oil tem-
perature switch. See Wiring Diagram.
21. Using a 8mm wrench, replace leads 5F and
239 to the engine alternator.
22. Using a 1/2" wrench, replace the two bolts to
the engine side cover.
23. Connect the following leads: (See Wiring
Diagrams)
238A (replace to engine starter solenoid)
231 (replace to engine starter solenoid)
5N, 5F & Ground lead (replace to negative bat-
tery grounding terminal)
226 & 5S to the fuel shutdown hold coil.
24. Using pliers, reconnect the fuel return line.
25. Turn ON the fuel stop valve. Check for leaks.
26. Using a 1/2" wrench, replace the negative bat-
tery cable.
27. Perform the Case Cover Replacement
Procedure.
® 500/600
F-58