Lincoln Electric BIG RED IM10019 User manual

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BIG RED 600
™
OPERATOR’S MANUAL
IM10019
August, 2009
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.
For use with machines having Code Numbers: 11599
Copyright © Lincoln lobal Inc.

FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz-
ing on contact with 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 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.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS IN URY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, 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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For asoline Engines

ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform 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 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.
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. round the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ii
SAFETY
ii
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and AC IH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09

FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. round the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and C A publication P-l,
“Precautions for Safe Handling of Compressed ases in
Cylinders,” available from the Compressed as Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. 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.
iii
SAFETY
iii
Jan ‘09
Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv
SAFETY
iv
Mar. ‘93
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. arder tous les couvercles et dispositifs de sûreté à leur
place.

vv
Thank You for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: o to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’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 manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

vi
vi TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions........................................................................................................A-2
Location and Ventilation................................................................................................A-2
Storing...........................................................................................................................A-2
Stacking ........................................................................................................................A-2
Angle of Operation ........................................................................................................A-2
Lifting.............................................................................................................................A-2
High Altitude Operation.................................................................................................A-2
High temperature Operation..........................................................................................A-2
Towing...........................................................................................................................A-3
Vehicle Mounting...........................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3
Oil..................................................................................................................................A-3
Fuel ...............................................................................................................................A-3
Engine Break-In ............................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connection........................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-5
Spark Arrester ...............................................................................................................A-5
Welding Output Cables ........................................................................................................A-5
Auxiliary Power Receptacles, Residual Device Ready, Standby Power Connections .........A-6
Connection of Lincoln Electric Wire Feeders .......................................................................A-7
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Instructions................................................................................................................B-1
eneral 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 Operation................................................................................................................B-5
Stick ..............................................................................................................................B-5
Arc ouging ..................................................................................................................B-5
TI Welding ..................................................................................................................B-6
Constant Current Operation with Lincoln Wire Feeder .................................................B-7
Auxiliary Power.....................................................................................................................B-8
Simultaneous Welding and Power Loads .....................................................................B-8
________________________________________________________________________________
Accessories.....................................................................................................Section C
Optional Features..................................................................................................C-1
________________________________________________________________________

Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Engine Maintenance ...........................................................D-1
Oil Filter Change .............................................................................................D-2
Air Filter Change .............................................................................................D-2
Fuel and Bleeding the Fuel System ................................................................D-2
Fuel Filters ......................................................................................................D-3
Fuel Pre-Filter/Water Separator Assembly .....................................................D-3
Water Separator Element ...............................................................................D-3
Second Fuel Filter...........................................................................................D-4
Cooling System...............................................................................................D-4
Cooling Blower Belt.........................................................................................D-4
Battery Handling ...............................................................................D-4 thru D-5
Servicing Optional Spark Arrestor .........................................................................D-5
Nameplates / Warning Decals ........................................................................D-5
Welder / enerator Maintenance ..........................................................................D-6
Storage ...........................................................................................................D-6
Cleaning..........................................................................................................D-6
Brush Removal and Replacement ..................................................................D-6
FCI Module Testing and Resetting Procedure .............................................D-6
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting uide.......................................................................E-1
Troubleshooting uide...................................................................................E-2, E-3
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Instructions for Installing a Residual Current Device......................................F-1, F-2
Wiring Diagram ......................................................................................................F-3
Dimension Print......................................................................................................F-4
________________________________________________________________________
Parts List...................................................................................................P-619 SER ES
________________________________________________________________________
viivii TABLE OF CONTENTS

A-1
INSTALLATION
BIG RED™ 600
A-1
TECHNICAL SPECIFICATIONS - BIG RED™ 600 (K2811-1)
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 ngine @ 1800 RPM Full Load 1800 75.7L
Bore x Stroke Oil:
3.94” x 4.72” 9.5 QTS.
(100mm x 120mm) 9.0L
INPUT - DIESEL ENGINE
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
2. To Top of enclosure, add 8.28”(210.1mm) to top of exhaust pipe.
RATED OUTPUT @ 104° F (40° C) - WELDER
HE GHT W DTH DEPTH WE GHT
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 Cycle
500A / 40V / 100%
550A / 34V / 60%
600A / 30V / 40%
250A / 20V / 100%
VOLTS
120
120
240
AMPS
20
15
15
POWER
2400 Watts
1800 Watts
3600 Watts
Auxiliary Power 1
Single Phase 60 Hz AC
PHYS CAL D MENS ONS
RATED OUTPUT @ 104° F (40° C).- GENERATOR
1657 lbs. (752 kg.)
RECEPTACLES AUX L ARY POWER C RCU T BREAKER OTHER C RCU T BREAKERS
1 - 120VAC Duplex N MA(5-20R) GFCI protected 1 - 20 AMP for 120 VAC Duplex (N MA)
1 - 120VAC uropean (I C-309)-GFCI protected 1 - 15 AMP for 120 VAC uropean (I C-309) 20AMP for Battery Charging Circuit
1 - 240VAC uropean (I C-309) 1 - 15 AMP for 240 VAC uropean (I C-309)
RECEPTACLES AND C RCU T BREAKERS

A-2
INSTALLATION
BIG RED™ 600
A-2
SAFETY PRECAUT ON
Read this entire installation section before you start
installation.
LOCAT ON AND VENT LAT ON
The welder should be located to provide an unrestrict-
ed 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.
STOR NG
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 con-
struction activities, moving vehicles, and other
hazards.
2. Drain the engine oil and refill with fresh 10W30
oil. Run the engine for about five minutes to cir-
culate oil to all the parts. See the MAINT -
NANC section of this manual for details on
changing oil.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
STACK NG
BIG R D™ 600 machines cannot be stacked.
ELECTR C SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• nsulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENG NE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOV NG PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
WARN NG
ANGLE OF OPERAT ON
To achieve optimum engine performance the BIG
R D™ 600 should be run in a level position. The
maximum angle of operation for the Deutz engine is
30 degrees fore and aft, 40 degrees right and 45
degrees left. If the engine is to be operated at an
angle, provisions must be made for checking and
maintaining the oil level at the normal (FULL) oil
capacity in the crankcase. When operating the welder
at an angle, the effective fuel capacity will be slightly
less than the amount specified.
L FT NG
The BIG R D™ 600 weighs approximately 1772lbs.
(804kg.) with a full tank of fuel 1657lbs.(752kg) less
fuel. A lift bail is mounted to the machine and should
always be used when lifting the machine.
H GH ALT TUDE OPERAT ON
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder output 5% for
every 300 meters (984 ft.) above 1500 meters (4920
ft.). For output of 500A and below, derate the welder
output 5% for every 300 meters (984 ft.) above 2100
meters (6888 ft.).
Contact a Deutz Service Representative for any
engine adjustments that may be required.
H GH TEMPERATURE OPERAT ON
WELDER OUTPUT RAT NGS AT
TEMPERATURES ABOVE 40°C
AMPS DUTY CYCLE VOLTS TEMPERATURE
450 DC 30% 38 55 ° C
500 DC 30% 40 50 ° C
550 DC 30% 34 45 ° C
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when lift-
ing.
• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
FALL NG • Do not lift machine if lift bail is
EQU PMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
--------------------------------------------------------------------------------
WARN NG

A-3
INSTALLATION
BIG RED™ 600
A-3
TOW NG
Use a recommended trailer for use with this equip-
ment for road, in-plant and yard towing by a vehi-
cle(1). If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment
and usage does not result in a safety hazard or dam-
age the welding equipment. Some of the factors to be
considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions; like maintenance.
5. Conformance with federal, state and local laws.(1)
(1) Consult applicable federal, state and local laws regarding spe-
cific requirements for use on public highways.
VEH CLE MOUNT NG
mproperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads 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-OPERAT ON ENG NE SERV CE
R AD the engine operating and maintenance instruc-
tions supplied with this machine.
Stop engine while fueling.
• Do not smoke when fueling.
• Keep spa ks and flame away
f om tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clea befo e sta ting
engine.
• Do not ove fill tank, fuel expan-
sion may cause ove flow.
DIESEL FUEL ONLY
------------------------------------------------------------------------------------------
O L
The BIG R D™ 600 is shipped with the engine
crankcase filled with high quality SA 10W-30 oil (API
class CD or better). Check the oil level before starting
the engine. If it is not up to the full mark on the dip
stick, add oil as required. Check the oil level every
four hours of running time during the first 35 running
hours. Refer to the engine Operator’s Manual for spe-
cific oil recommendations and break-in information.
The oil change interval is dependent on the quality of
the oil and the operating environment. Refer to the
engine Operator’s Manual for the proper service and
maintenance intervals. The machine is equipped with
an oil drain valve.
FUEL
USE D ESEL FUEL ONLY
• Fill the fuel tank with clean, fresh fuel. The
capacity of the tank is 20 gals. (75.7 ltrs). When
the fuel gauge reads empty the tank contains
approximately 2 gals. (7.6ltrs.) of reserve fuel.
NOTE: A fuel shut off valve is located on the pre-
filter/sediment filter. Which should be in
the closed position when the welder is not
used for extended periods of time.
------------------------------------------------------------------------
WARN NG
WARN NG
D ESEL FUEL
can cause fire.
WARN NG
WARN NG

A-4
INSTALLATION
BIG RED™ 600
A-4
ENG NE BREAK- N
Lincoln lectric selects high quality, heavy-duty indus-
trial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wetstacking (oil or tar like sub-
stance at the exhaust port), or excessive smoke is not
normal.
Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load condi-
tions for extended periods of time are especially sus-
ceptible to the conditions described above. To
accomplish successful engine break-in, most diesel-
powered equipment needs only to be run at a reason-
ably heavy load within the rating of the welder for
some period of time during the engine’s early life.
However, if the welder is subjected to extensive light
loading, occasional moderate to heavy loading of the
engine may sometimes be necessary. Caution must
be observed in correctly loading a diesel/generator
unit. 1. Connect the welder output studs to a suit-
able resistive load bank. Note that any
attempt to short the output studs by con-
necting the welding leads together, direct
shorting of the output studs, or connecting
the output leads to a length of steel will
result in catastrophic damage to the gener-
ator and voids the warranty.
2. Set the welder controls for an output cur-
rent and voltage within the welder rating
and duty cycle. Note that any attempt to
exceed the welder rating or duty cycle for
any period of time will result in catastrophic
damage to the generator and voids the
warranty.
3. Periodically shut off the engine and check
the crankcase oil level.
ENG NE COOL NG 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 CONNECT ON
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOS ON when:
• NSTALL NG A NEW BATTERY — disconnect
negative cable from old battery first and connect
to new battery last.
• CONNECT NG A BATTERY CHARGER — remove
battery from welder by disconnecting negative
cable first, then positive cable and battery clamp.
When reinstalling, connect negative cable last.
Keep well ventilated.
• US NG A BOOSTER — connect positive lead to
battery first then connect negative lead to nega-
tive battery lead at engine foot.
BATTERY AC D can burn eyes and skin.
• Wear gloves and eye protection and
be careful when working near battery.
• Follow instructions printed on battery.
MPORTANT:To prevent ELECTR CAL DAMAGE
WHEN:
a) nstalling new batteries.
b) Using a booster.
Use correct polarity —Negative Ground.
------------------------------------------------------------------------
The BIG R D™ 600 is shipped with the negative bat-
tery cable disconnected. Before you operate the
machine, make sure the ngine Switch is in the OFF
position and attach the disconnected cable securely to
the negative (-) battery terminal.
Remove the insulating cap from the negative battery
terminal. Replace and tighten negative battery cable
terminal.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be sure to use the correct
polarity when charging the battery.
WARN NG

A-5
INSTALLATION
BIG RED™ 600
A-5
MUFFLER OUTLET P PE
Remove the plastic plug covering the muffler outlet
tube. Using the clamp provided secure the outlet pipe
to the outlet tube with the pipe positioned such that it
will direct the exhaust in the desired position.
SPARK ARRESTOR
Some federal, state or local laws may require that
petrol or diesel engines be equipped with exhaust
spark arrestors when they are operated in certain
locations where unarrested sparks may present a fire
hazard. The standard muffler included with this welder
does not qualify as a spark arrestor. When required by
local regulations, a suitable spark arrestor, must be
installed and properly maintained.
An incorrect arrestor may lead to damage to the
engine or adversely affect performance.
------------------------------------------------------------------------
WELD NG OUTPUT CABLES
With the engine off, connect the electrode and work
cables to the output studs. The welding process dic-
tates the polarity of the electrode cable. These con-
nections should be checked periodically and tightened
if necessary.
Listed in Table A.1 are copper cable sizes recom-
mended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work
and back to the welder again. Cable sizes are
increased for greater lengths primarily for the purpose
of minimizing cable voltage drop.
Table A.1 Combined Length of Electrode and
Work Cables.
MACH NE GROUND NG
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 equipment
powered by this engine driven welder must:
a) be grounded to the frame of the welder using
a grounding type plug,
or
b) be double insulated.
When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the sec-
tion entitled “Standby Power Connections” as well as
the article on grounding in the latest National
lectrical Code and the local codes.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal ground stake going into
the ground for at least 10 Feet or to the metal frame-
work of a building which has been effectively ground-
ed. The National lectric Code lists a number of alter-
nate means of grounding electrical equipment. A
machine grounding stud marked with the symbol
is provided on the front of the welder.
CAUTION
AMPS Upto150 ft. 150-200 ft. 200-250 ft.
@100% (Upto45m) (45-60m) (60-75m)
Duty Cycle
500 3/0 AWG 3/0 AWG 4/0 AWG
95mm295mm2120mm2
TOTAL COMB NED LENGTH OF ELECTRODE
AND WORK CABLES

A-6
INSTALLATION
BIG RED™ 600
A-6
AUX L ARY POWER RECEPTACLES
The auxiliary power of the BIG R D™ 600 consists of
Single Phase 60Hz Power. Out put Voltage is within
+/- 10% at loads up to rated capacity.
One 120VAC N MA (5-20R) 20 amp duplex recepta-
cle is protected by a 20 amp circuit breaker that pro-
vides 2400 watts Peak / 2400 watts Continuous
power. Maximum current is 20 amps total.
One 120VAC uropean (I C-309) 16 amp receptacle
is protected by a 15 amp circuit breaker that provides
1800 watts Peak / 1800 watts Continuous power.
Maximum current is 15 amps.
One 240VAC uropean (I C-309) 16 amp receptacle
is protected by a 15 amp 2-pole circuit breaker that
provides 3600 watts Peak / 3600 watts Continuous
power. The 2-pole circuit breaker disconnects both hot
leads at the same time. Maximum current is 15 amps.
120 V RECEPTACLES
A GFCI module protects, the two 120V Auxiliary
Power receptacles. A GFCI (Ground Fault Circuit
Interrupter) electrical receptacle is a device to protect
against electric shock should a piece of defective
equipment connected to it develop a ground fault. If
this situation should occur, the GFCI module will trip,
removing voltage from the output of the receptacle. If
a GFCI module is tripped see the MAINT NANC
section for detailed information on testing and reset-
ting it. A GFCI module should be properly tested at
least once every month.
The 120 V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at
least equal to the current capacity of the associated
receptacle.
RES DUAL CURRENT DEV CE READY
The BIG R D™ 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 R D™ 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 of the
panel.
Note: The (RCD) should be rated for at least 15 amps.
There are many suppliers of RCD’s. One example is
Allen Bradley, part number 1492-RCD2A40.
The protective boot can be obtained from:
APM-Hexseal, part number H -1035
See Section F Diagrams of this Operator’s Manual for
instructions on installing an RCD and protective rub-
ber boot.
STANDBY POWER CONNECT ONS
The BIG R D™ 600 is suitable for temporary, standby
or emergency power using the engine manufacturer’s
recommended maintenance schedule.
The BIG R D™ 600 can be permanently installed as
a standby power unit for 240 VAC(60Hz). Connections
must be made by a licensed electrician who can
determine how the 120/240 VAC power can be adapt-
ed to the particular installation and comply with all
applicable electrical codes.
Take necessary steps to assure load is limited to the
capacity of the BIG R D™ 600
• Only a licensed, certified, trained electrician
should install the machine to a premises or resi-
dential electrical system. Be certain that:
• The installation complies with the National
Electrical Code and all other applicable electrical
codes.
• The premises is isolated and no feedback into
the utility system can occur. Certain state and
local laws require the premises to be isolated
before the generator is linked to the premises.
Check your state and local requirements.
------------------------------------------------------------------------
WARN NG

A-7
INSTALLATION
BIG RED™ 600
A-7
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Shut off Welder before making any electrical con-
nections.
------------------------------------------------------------------------
The LN-15™ Across-the-Arc model, LN-25™ with or
without an internal contactor, and LN-25™ PRO may
be used with the BI RED™ 600.
1. Shut the welder off.
2. For electrode Positive, connect the electrode cable
from the wire feeder to the “+” terminal of the
welder and work cable to the “-” terminal of the
welder. For electrode Negative, connect the elec-
trode cable from the wire feeder to the “-” terminal
of the welder and work cable to the “+” terminal of
the welder.
3. Set the CV/CC mode of the wire feeder to CC.
(Refer to wire feeder operator manual for details on
setting the wire feeder in the CC mode and for set-
ting welding parameters).
4. Attach the single 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) can-
not be used with the BI RED™ 600 See the
appropriate connection diagram in Section F.
If you are using an LN-25™ without an internal
contactor, the electrode will be energized when
the BIG RED™ 600 is started.
------------------------------------------------------------------------
The Wire Feeder sensor has full OCV potential
between spring clip and work return. Turn
machine off when attaching spring clip.
------------------------------------------------------------------------
Lincoln Electric does NOT recommend constant
current semiautomatic welding for applications
which need to meet specified weld metal chemical
or mechanical property requirements or weld
quality requirements.
------------------------------------------------------------------------
WARN NG
WARN NG
BIG RED™ 600
Wor k
Electrode
Work clip
LN-15™ ACROSS THE ARC
LN-25™, LN-25™ PRO
F GURE A-1

B-1
OPERATION
B-1
GENERAL DESCR PT ON
The BIG R D™ 600 is a diesel engine driven welder,
offering reliable DC arc welding performance, with
outstanding arc characteristics for all welding applica-
tions. The BIG R D™ 600 is both a rugged three
cylinder, diesel engine driven 600 amp DC arc welder
and 3.6 KW AC power generator. This powerful gen-
erator can be used to provide electricity for lights,
power tools, etc.
The BIG R D™ 600 delivers ideal DC arc characteris-
tic for each welding process. Stick electrode welding,
Scratch-Start TIG, or carbon arc gouging, to make the
BIG R D™ 600 the ideal all purpose engine driven
welder for on-site work.
The BIG R D™ 600 has “no PC Boards” and “no
electronics”.
The BIG R D™ 600 is service friendly with a minimal
number of major parts, simplifying in field servicing of
the BIG R D™ 600. The generator is a dual stator
and rotor design with two sealed bearings for mainte-
nance free service. The rotors are copper wound
design with two slip rings and brushes. The stators
are wound entirely with heavy gauge copper wire and
insulated with N MA class F insulation material. The
stator is then impregnated with three layers of high
quality varnish. After the stator is assembled using tie
bars, the entire assembly Is covered with an environ-
mentally protective coating . These measures insure
trouble-free operation in the harshest environments.
RECOMMENDED APPL CAT ONS
WELDER
The BIG R D™ 600 provides constant current DC
welding 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 R D™ 600 is not recommended for pipe
thawing.
GENERATOR
The BIG R D™ 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 settings. Full power is available provided
welding output is below 200 amps. Above 200 amps refer to
the Simultaneous Welding and Auxiliary Power chart in the
operation section of this manual.
BIG RED™ 600
SAFETY NSTRUCT ONS
Read and understand this entire section before
operating your B G RED™ 600.
Do not attempt to use this equipment until you
have thoroughly read all operating and mainte-
nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.
ELECTR C SHOCK can kill.
• Do not touch electrically live parts
such as output terminals or internal
wiring.
• nsulate yourself from the work and
ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENG NE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside
• Do not stack anything near the engine.
------------------------------------------------------------------------
MOV NG PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should operate this
equipment.
------------------------------------------------------------------------
ADD T ONAL SAFETY PRECAUT ONS
Always operate the welder with the hinged door
closed and the side panels in place as these pro-
vide maximum protection from moving parts and
insure proper cooling air flow.
------------------------------------------------------------------------
WARNING

B-2
OPERATION
B-2
WELD NG CONTROLS ( tems 1-5)
1. OUTPUT RANGE SELECTOR SW TCH
A 5 position switch that provides 5 overlapping out-
put current settings:
• 65 - 115
• 105 - 220
• 150 - 330
• 200 - 435
• 300 – Maximum
Note: Do not switch while welding
2. OUTPUT CONTROL
Provides fine adjustment of the current and open
circuit voltage from minimum to maximum within
each Range.
“1’’ is minimum and “10” is maximum.
3. WELD MODE SELECTOR SW TCH
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 SETT NGS
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
3
1
9
4
8
7
11
12
2
14
13
21
5
6
10
15 16 17 18 19
20
22

B-3
OPERATION
B-3
5. LOCAL / REMOTE CONTROL SW TCH and
REMOTE RECEPTACLE
The toggle switch provides the option of controlling
the welding output at the control panel or remotely.
For control at the control panel set the switch in the
"LOCAL" position. For remote control set the switch
in the "R MOT " position. The receptacle is for
attaching an optional remote control equipment.
(See Accessory Section For “K” number)
ENG NE CONTROLS ( tems 6 Through to 13)
6. ENG NE HOUR METER / FUEL GAUGE
Combination hour meter fuel level gauge. The hour
meter displays the total time that the engine has
been running. This meter is a useful indicator for
scheduling preventive maintenance. The fuel gauge
displays the level of diesel fuel in the fuel tank. The
operator must watch the fuel level closely to pre-
vent running out of fuel and possibly having to
bleed the system.
7. RUN STOP SW TCH
The RUN position energizes the hold coil of the fuel
solenoid, hour meter, and rotor flashing circuit. The
STOP position stops the engine.
Note: Do not leave switch in RUN position when the
engine is not running. In the RUN position the
battery will be discharged.
8. START PUSH BUTTON
nergizes the starter motor to crank the engine.
With the RUN / STOP switch in the RUN position,
push and hold the Start button to crank the engine;
release as the engine starts. Do not press while
engine is running as this can cause damage to the
ring gear and/or starter motor.
9. C RCU T BREAKER
The battery circuit breaker protects the engine cir-
cuitry that powers the three gauges, fuel/hours,
temperature and pressure. It also protects the
engine shutdown relay, timer delay relay, hot start
relay hold solenoid, and flashing circuitry. When the
circuit breaker opens because of a fault, the engine
will crank but will not start.
10. O L TEMPERATURE GAUGE
An indicator of engine oil temperature.
11. O L PRESSURE GAUGE
An indicator of engine oil pressure.
12. ENG NE PROTECT ON
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 the light will turn on and the engine pro-
tection system will stop the engine. The light will
remain on when the engine has been shut down.
In order to try and re-start the engine the engine
protection system must be reset by returning the
RUN-STOP switch to the STOP position.
Note: The light remains off when the RUN-STOP
switch is in the RUN position prior to starting the
engine. However if the engine is not started within
60 seconds the light will come on. When this hap-
pens the RUN-STOP switch must be returned to
the STOP position to reset the engine protection
system and light.
13. BATTERY CHARG NG L GHT
An indicator light for low/no battery charging. The
light is off when the battery charging system is
functioning normally. If light turns on, the alterna-
tor or the voltage regulator may not be operating
correctly or the cooling blower belt may be broken.
The light will remain on when the engine is
stopped and the RUN / STOP switch is in the RUN
position.
AUX L ARY POWER (14-22)
14. C RCU T BREAKER
2-pole 15A rated. Provides overload protection for
the 240VAC uropean (I C-309) receptacle.
15. 240 VAC RECEPTACLE
uropean (I C-309) receptacle rated up to 15
amps and is IP44 rated.
Note: A space is provided on the panel for adding a 2-
pole Residual Current Device (RCD) to protect the
240V receptacle. See Section F for instructions on
installing an RCD.
16. C RCU T BREAKER
Single-pole 20A rated. Provides overload protec-
tion for the 120VAC (5-20R) N MA Duplex
Receptacle.
BIG RED™ 600

B-4
OPERATION
B-4
17. 120 VAC DUPLEX RECEPTACLE
Single-pole 20A rated. Provides overload protec-
tion for the 120VAC (5-20R) N MA Duplex
Receptacle.
18. C RCU T BREAKERS
Single pole 15A rated. Provides overload protection
for the 120VAC uropean (I C-309) receptacle.
19. 120 VAC RECEPTACLE
uropean (I C-309) receptacle rated up to 15 amps
and is IP44 rated. Receptacle is GFCI protected.
20. GFC (Ground Fault Circuit nterrupter) Module
Protects both 120VAC Auxiliary Power recepta-
cles.
If a FCI Module is tripped, See the MAINTE-
NANCE section for detailed information on testing
and resetting the FCI Module.
21. WELD OUTPUT TERM NALS + AND -
Covered terminals that provide welding connection
points for the electrode and work cables.
22. GROUND STUD
Protects both 120VAC Auxiliary Power recepta-
cles.
ENG NE OPERAT ON
START NG THE ENG NE
1. Open the engine compartment door and check
that the fuel shut off valve located screwed into
the fuel filter housing is in the open position (lever
to be in line with the hose).
2. Check for proper oil level. Close engine compart-
ment door.
3. Remove all plugs connected to the AC power
receptacles.
4. Set the RUN/STOP switch to “RUN”. Observe that
the battery charging light is on and fuel is in the
fuel tank (see fuel gauge).
5. Within 30 seconds, press and hold the engine
START button until the engine starts.
6. Release the engine START button when 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 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 START NG
With a fully charged battery and the proper weight
oil, the engine should start satisfactorily even down
to about -15°C(5°F). If the engine must be frequent-
ly started below -15°C(5°F), it may be desirable to
install additional starting aids. The use of No. 1D
diesel fuel is recommended in place of No. 2D at
temperatures below -5°C(23° F).
STOPP NG THE ENG NE
Switch the RUN/STOP switch to “STOP”. This
turns off the voltage supplied to the shutdown sole-
noid. A backup shutdown can be accomplished by
shutting off the fuel valve located on the fuel line.
Note: Also put Run/Stop switch in “Stop” position
when engine is not running - battery will be
discharged otherwise.
BIG RED™ 600
TYP CAL B G RED™ 600 FUEL CONSUMPT ON
TABLE B.1
Deutz F3L912 Engine
44HP (33Kw) @ 1800 RPM
2.6 liters/hr
(.69 gal/hr)
7.5 liters/hr
(1.97 gal/hr)
4.4 liters/hr
(1.16 gal/hr)
3.0 liters/hr
(.78 gal/hr)
Running Time for
75.7 L (20 Gal.)
28.9 hrs
10.1 hrs
17.2 hrs
25.5 hrs
High Idle - No Load
1890 R.P.M.
DC, CC Weld Output
500A/40V/100%
DC, CC Weld Output
600A/30V/40%
Auxiliary Power
3.6 Kw
NOTE: This data is for reference only. Fuel consump-
tion is approximate and can be influenced by many
factors, including engine maintenance, environmental
conditions and fuel quality.

B-5
OPERATION
B-5
WELDER OPERATION
DUTY CYCLE
Duty Cycle is the percentage of time the load is
being applied in a 10 minute period. For example a
60% duty cycle, represents 6 minutes of load and 4
minutes of no load in a 10 minute period.
ELECTRODE INFORMATION
The BI RED™ 600 is designed for horizontal, ver-
tical up, and overhead welding with all types of DC
stick electrodes.
For any electrode the procedures should be kept
within the rating of the machine. For information on
electrodes and their proper application see
(www.lincolnelectric.com) or the appropriate
Lincoln publication.
WELDING MODE
Set the Welding mode switch for the desired
process, either Stick / ouging or TI .
CONSTANT CURRENT STICK WELDING
DO NOT TURN THE “OUTPUT RANGE SELEC-
TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
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The “Output Range Selector” provides five overlap-
ping current ranges. The “Output Current
Adjustment” adjusts the current from minimum to
maximum within each range. Open circuit voltage is
also controlled by the “Output Current Adjustment”
permitting control of the arc characteristics.
A high open circuit voltage setting provides the soft
“buttering” 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
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 forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Output
Range Selector” setting and lower open circuit volt-
age.
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” set-
ting to get 175 amps.
Some arc instability may be experienced with
EXX10 electrodes when trying to operate with long
arc techniques at settings at the lower end of the
open circuit voltage range.
DO NOT attempt to set the “Current Range
Selector” between the five points designated on
the nameplate.
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ARC GOUGING
Using the “Output Range Selector” and “Output
Control Adjustment” set the output to the desired
level for the gouging electrode being used see
table B.2.
BIG RED™ 600
Carbon Diameter Current Range (DC, elec-
trode positive)
1/8"(3.2mm) 60-90 Amps
5/32"(4.0mm) 90-150 Amps
3/16"9(4.8mm) 200-250 Amps
1/4"(6.4mm) 300-400 Amps
5/16"(8.0mm) 350-450 Amps
3/8"(9.5mm) 450-600 Amps
TABLE B.2
CAUTION
CAUTION