Lincoln-electric IM10025 BIG RED 500 User Manual

IM10025-AMarch 2013Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safety

A-2INSTALLATION BIG RED™ 500A-2SAFETY PRECAUTIONRead this entire installation section before you startinstallation.LOCATION AND VENTILATIONThe welde

A-3INSTALLATION BIG RED™ 500A-3TOWINGUse a recommended trailer for use with this equip-ment for road, in-plant and yard towing by a vehi-cle(1). If

A-4INSTALLATION BIG RED™ 500A-4ENGINE BREAK-INLincoln Electric selects high quality, heavy-duty indus-trial engines for the portable welding machine

A-5INSTALLATION BIG RED™ 500A-5MUFFLER OUTLET PIPERemove the plastic plug covering the muffler outlettube. Using the clamp provided secure the outle

A-6INSTALLATION BIG RED™ 500A-6AUXILIARY POWER RECEPTACLESThe auxiliary power of the BIG RED™ 500 consists ofSingle Phase 60Hz Power. Output Voltage

A-7INSTALLATION BIG RED™ 500A-7CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERSShut off Welder before making any electrical con-nections.---------------

B-1OPERATIONB-1GENERAL DESCRIPTIONThe BIG RED™ 500 is a diesel engine driven welder,offering reliable DC arc welding performance, withoutstanding arc

B-2OPERATIONB-2WELDING CONTROLS (Items 1-5)1. OUTPUT RANGE SELECTOR SWITCHA 5 position switch that provides 5 overlapping out-put current settings:•

B-3OPERATIONB-35. LOCAL / REMOTE CONTROL SWITCH andREMOTE RECEPTACLEThe toggle switch provides the option of controllingthe welding output at the cont

B-4OPERATIONB-417. 120 VAC DUPLEX RECEPTACLE120VAC (5-20R) NEMA Duplex Receptacle.Receptacle is GFCI protected.18. CIRCUIT BREAKERSSingle pole 15A rat

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-5OPERATIONB-5WELDER OPERATIONDUTY CYCLEDuty Cycle is the percentage of time the load isbeing applied in a 10 minute period. For example a60% duty cy

B-6OPERATIONB-6TIGThe BIG RED™ 500 can be used for Scratch-Startof DC TIG welding applications.Use the “Output Range Selector” and “OutputControl Adju

B-7OPERATIONB-7CONSTANT CURRENT OPERATION WITHA LINCOLN ELECTRIC WIRE FEEDERLincoln Electric does NOT recommend constantcurrent semiautomatic welding

B-8OPERATIONB-8BIG RED™ 500AUXILIARY POWER:The auxiliary power is independent of the weldingpower and thus not effected by the weld control set-tings.

C-1ACCESSORIESC-1BIG RED™ 500OPTIONAL FEATURESK2641-2 FOUR WHEELED STEERABLE YARDTRAILERFor in plant and yard towing. Comes standard with aDuo-Hitch™,

D-1MAINTENANCED-1BIG RED™ 500SAFETY PRECAUTIONSHave qualified personnel do the maintenancework. Turn the engine off before working insidethe machine.

D-2MAINTENANCED-23. Remove loose dirt from element with compressed airor water hose directed from inside out.Compressed Air: 100 psi maximum with nozz

BATTERY HANDLINGGASES FROM BATTERY can explode.• Keep sparks, flame and cigarettes awayfrom battery.To prevent EXPLOSION when:• INSTALLING A NEW BATTE

D-4MAINTENANCED-4PREVENTING BATTERY BUCKLINGTighten nuts on battery clamp until snug.CHARGING THE BATTERYWhen you charge, jump, replace, or otherwise

D-5MAINTENANCED-5WELDER / GENERATOR MAINTENANCESTORAGEStore the BIG RED™ 500in clean, dry protected areas.CLEANINGBlow out the generator and controls

ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when welding or obs

E-1TROUBLESHOOTINGE-1BIG RED™ 500If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contac

E-2TROUBLESHOOTINGE-2BIG RED™ 500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

E-3TROUBLESHOOTINGE-3BIG RED™ 500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

F-1DIAGRAMSF-1BIG RED™ 500AM22253ELECTRICSHOCKCAN KILLWARNINGDo not operate with covers removedDisconnect input power before servicingDo not touch ele

F-2DIAGRAMSF-2BIG RED™ 500M22253A4. LOCATE LEADS 3D & 6J. (SEE FIGURE 2). CUT BOTH LEADS AS SHOWN. 5. STRIP ALL FOUR LEADS 13MM (.50 i

F-3DIAGRAMSF-3BIG RED™ 500NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific d

F-4DIAGRAMSF-4BIG RED™ 500NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific d

F-5DIAGRAMSF-5BIG RED™ 500A.01M2225 265.101653.727.00685.810.01254.36.29159.81.2832.523.32592.231.70805.246.501181.159.501511.3N.A. CENTER OF GRAVITY

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

Need Help?Lincoln Electric “Rapid Response” Service!Call 1.888.935.3877 to talk to a Service RepresentativeHours of Operation: 8:00 AM to 6:00 PM (ET)

ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra

vvThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much

viviTABLE OF CONTENTSPageInstallation...

PageMaintenance .......Section DSafety Precautions ...

A-1INSTALLATION BIG RED™ 500A-1TECHNICAL SPECIFICATIONS - BIG RED™ 500 (K2810-1)Make/Model Description Speed (RPM) Displacement Starting Capacities