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MEGA-ARC® 40300 - Victor Technologies
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1. 1 z 8 5 EREE VAPRUS que 4 0 680008 a D pene W a kul fe pre e rani Z 13365 ON 3m xus Sapam hao TMUGANOS 00 12 2 Bree WSS LON mawo 089 F 007 4 00 12 4 51753538 wwe DO 20500 en meme unpre 210 1 5 2 F 7 GOL NOLO3NNOO TM Jun PORES CRON CT 5144 CG3N9IS30 MOQNGA 804 KOTIA 20 N BY SHOSX MKI or EE reum 494034 ISIMYBHLO SSINN E 00 12 4 25480008 2B m ane ma o 100008 3002 HSINIJ GHOST 2 a 1 MES H gr it SONIONIM 25 J L NOILV1I9X3 1 Hs YU 15 319 E SONIONIM PT Jo
2. clear odorless colorless Solubility in Water completely Boiling Point approximately 235 F Specific Gravity H0 1 1 220 1 325 Evaporation Rate Butyl Acetate 1 less than 1 0 Vapor Density AIR 1 N A Melting P Vapor Pressure mm Hg 13 hydrogen gas LEL 45 Flash Point Method Used non flammable Flammable Limits Extinguishing Media Class ABC extinguisher CO and or Halon UEL 74 Special Fire Fighting Procedures Cool exterior of battery if exposed to fire to prevent rupture The acid mist and vapors in a fire situation are corrosive Wear special respiratory protection SCBA and clothing Unusual Fire and Explosion Hazards Hydrogen gas which may explode if ignited is produced by this battery especially when charging Use adequate ventilation avoid open flames sparks or other sources of ignitio Stability Stable Condition to Avoid Cases decompose at 160 410 C 322 770 F Incompatibility Materials to Avoid Strong oxidizing agents such as hot nitric acid etc Hazardous Decomposition of By Products Combustion can produce carbon dioxide CO and carbon monoxide CO Conditions to Avoid not applicable Hazardous Polymerization will not occur Page 1 of 2 MSDS Battery Wet Filled with Acid 8 UN2794 page 2 of 2 Route s of Entry Inhalation skin contact and inge
3. Dy 1510 WA ALUATIO AU 100008 3003 HSINIJ Tui 3NON NOUNERUSIO MASIO 306110 00934 39NVH2 709 HOLIMS QION310S NI HOLMS 9334 QION310S NMOGLNHS NMOGINHS NOIL103iOHd 3NION3 TYNOILdO 3101 OLAY VNOlLdO 330435 349435 39435 38055384 H3LINHNOH 39nvo 7303 HOLIMS GION310S H31NVIS 34NSS3ud 10 LIOA ZI NMOGLOHS AL34VS ipe 30010 FIS M019 01043105 1NVIS X3H13 Q3TWISNI SI 18415 l V3 J3HL3 N3HM 193NNOOSIQ NOLINEHSNd 14415 Statement Warranty LIMITED Thermal Are A Thermadyne Company warrants that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized
4. YIBNNN 01 035 3009 80103 Id 1031405 40300 300 Amp Constant Current Diesel Engine Driven Welding Generator For the Following Specs 6298 1 Built After January 1 2000 Having Serial Nos TOO IHERMAL Company ADDENDUM OWNER S MANUAL Number 430429 427 Issued February 21 2000 IMPORTANT Read these instructions before installing operating or servicing this system THERMAL ARC INC TROY OHIO 45373 1085 U S A 430429 427 ADDENDUM Figure A February 21 2000 430429 427 ADDENDUM Parts List for Figure A Quantity Recomm Item Part Description Qty Spares No Number per Class 1 Class 2 Assy 67 406149 Fan Engine 1 68 Deleted 69 494181 Alternator Delco 1 W 9360 229 Cable Bonding 1 70 494149 2 Sender Water Temp 1 71 No Number Filter Fuel Supplied W Engine 1 72 491721 2 Bracket Mtg Fuel Filter 1 73 492362 3 Panel Front 1 74 491689 23 Plate Front End 1 75 491690 2 Support Radiator 2 76 406981 1 Radiator 1 77 406989 Cap Radiator 1 78 W 10869 12 Clamp Hose 4 79 406977 Radiator 1 80 493252 2 Shroud Fan 1 81 405977 2 Hose Radiator Bottom 1 82 494741 Guard Fan 1 83 406001 Label Caution 2 84 494725 Brace Guard 1 85
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6. an T NOUVIIOX3 49 w SSNIGNIM ONIZINOMHONLS JHL Si S3A 323M HOIHM DYVOS Od 10HINOO AB G3TJOHINOO St ONIGIIM INdiNO IHL 179170 S10MINOO ONY SONIONIM QT3M NOJVS3N3O OY MOBS 10100 ONITI3M 20 31904 4334238 INdINO YI 249 5 825 53000 JO 55 2 184355 11938 114100 OL S 3SYHd Ol 3SVHd Ov SIOA 09 Al3tvWixONddY SONIGNIM TIIM TIIM 5310143239 01 M3MOd 3SvHd TIONIS SLIOA OFZ 021 4 5 OL 0357 Si ONIGNIM NOLIYIIOX3 3Hl 40 3svHd JNO SITOA 099 4 SI SHOIIOvdvO 9 3svHd OL 35 4 SONIONIA 35 4 Ol Q3103NNOO 13 112 SHOUOVAYI AB 3135 51 HOIVH3N39 JHL NOLV3H3dO JO TNA 98 04 SONIONIM DNIZINOHHONAS TOMINOO 01 3545 JOuLNOO LNGNNDO 71041 HOLIMS 7OMLNOO BO12Y1NOO 1041 HOLUMS HOLMS 39NvH quvog8 I d 831301 N310d 39804 ONV M3L3HOUN3lOd 10MLNO2 1934809 68 30151535 39NYM MOT EM 140 5 313 mi INNHS 9 89333 94 S L WHO OS 3019635 QYOT3Nd SWHO OS SHOLSIS3N 880 5 140 ZW 140 in
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8. 3MOHD 83174 1 Nid S ION3HdWY 310Y1d393M er 131100 KAY AOfZ 17000 XnV ASH 30123NNOO ONVOS eue 53514 GYVO8 10585 83 13 YIS 4 6 30010 3MOd g o v zua SM33Y3N8 oNINOS 5709 5 NOISS3HddNS 3SION AIN 907 SHOIIDYdYO 88 5 CEH L 2 5 2 9 8 ot 43 890008 a 1431 HO 3 08Y DL eq emt Rer 7065 ZZ AOTGA Up 120 A 08 LHS 40102 5 BANG STOS OU ES 00 ON3 NYE 3018 138 mem 03 1894 xovi8 NOUDINNOS 3NION3 3009 40702 penc 00808 Wwuovig M JUL 1600030 Al 000084 s SAW 53 04 ONE AKSES 934935 SSTNN 86 iZ L 17550000 100008 Wad 3402 03 111113 Tp owns ws
9. 40300 300 Amp Constant Current Diesel Engine Driven Welding Generator For the Following Specs 6298E 1 IHERMAL THEHMADYNE Company OWNER S MANUAL Number 430429 427 Rev AA Revised February 21 2000 THERMAL ARC INC TROY OHIO 45373 1085 U S A 430429 427 Table Contents CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm INTRODUCTION How To Use This Manual 1 1 Equipment Identification 1 1 Receipt 1 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 Generator ooo eR Sp Q eens wy br 3 1 ENNE unterm tede A Reef mere die eoe Mee ah eut amp nen 3 1 Identification 1e e Ae TS wl ee Ge a S 3 1 tabulated Data c s er oU EES 3 1 Supplementary Materials 3 2 Engine Controls and Instruments 3 2 Generator Controls DAR E 60 RUE bc an RUPEE 3 3 INSTALLATION 4 General Engine Driven Welder Installation 4 1 i ee S 4 1 Safe
10. 53 4 HO YWIS 3unss3ud M019 61 ed U SL 6 k xa 202 5 SI POS 5 R 5 Hi NS COE AVIS N3HIJ NJHM 38055384 8 38 zu E ab I P ase 7 St X8 98 5 9 ji si 9 2 90 192 is nOn 106179 C 8 3univedWal 61 6t I 1 M313WOHOVL le i 28155354 10 MOLWNSALTW Raps dini ie MNT 1491 SUALIN 3NIN3 TVNOLLdO Dn 6 5 UENO fv HMO z NMOTINHS 313345 INNOULdO 5 NOLLDINNOD 30010 66996 133HS t wo av 3514933 7051405 3IOMB3N8 4011934409 1091409 0 18 22 01 CIN MOM AMEN UVO 1014 66976 3NON 100008 93d 3002 HSINIJ aNd 28 1 251 VIS TVNINN31 VIS 9 1041 HOLMS 1041 5 1545 HOLAS XS AZ HALINONN3LOd HOISIS3N Nid 9 ION3HdMY 312V1d303H VIS 4 310V1d303M ONISNOH VIS Zi 310v1d303M 5 VIS 6 310V1d303M 5 1593 1 ISNA QN3931 030933 ENT 49 4337 YO 5 0102 O LE VIBNAN
11. NOM em INNO2SKI At pum 01115 G3TI1SNI r Eme 2 I ploy b e C anii s 6 30795 aa E 40 FE gt 15 SUUM TR pa 2 91043105 3101 z QIONTIOS S S P TaNvd PSS cue ted 025 Rabu ls 0334 1 404 18415 H3H13 TVNOLLdO 1 41 901 0 L MS 3OMINO2 03345 GNI9N3 305 Woes ZM IDAIG 3101 9 7 e UX NMOGLAHS NOLLO31OHd 3NI9N3 TYNOUdO MO1VNN3LTV t 4 AMiLIVH 6 noz 2E c to 1 Eo n 99 yaa 0 vi 9 7 2 T ya ez 0 N3ON3S TANA 530435 HOLMS a Vom Are 4 Bm 3uruviadnal atv 3unss3sd Wibwis NO 5 61 19 2 2 OF 6 r4 N 0 4 A ND 391 MONS 93193440550 38 ISON z 13 aL 71779 5 5 5 si B 38 sz ot 38 90E 01 8 5 ER X
12. Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards ENGINES can be hazardous 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes May 8 1996 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank
13. 9 10 491258 Figure 7 4 Control Board TEST TEST POINTS CALLOUTS VOLTAGE CONDITIONS REMARKS 1 TP N to TP E 2013 40 0 21 0 1800 Load 2 10 14 10 13 40 0 21 0 1800 Load 3 3013 20 0 1800 or Idle No Load 4 TP D to TP E 12 to 13 20 0 1800 or Idle No Load 5 TP A to TP E 4 to 13 15 0 1800 or Idle No Load 6 TP B to TP E 11 to 13 15 0 1800 Idle No Load 7 TP F to TP E 5 to 13 4 3 1800 or Idle No Load TP G to TP E 7 to 13 4 3 1800 or Idle No Load TP H to TP E 9 to 13 14 3 1800 or Idle No Load 8 TP J to TP E 6 to 13 18 3 1800 or Idle No Load TP K to TP E 8 to 13 18 3 1800 or Idle No Load L gt TP L to TP E 10 to 13 18 3 1800 or Idle No Load Table 7 2 August 24 1998 7 5 430429 427 TROUBLESHOOTING This page intentionally left blank 7 6 August 24 1998 430429 427 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described the Intro duction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembl
14. allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary To prevent accidental starting during servicing disconnect nega tive battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and put a rag over cap area when removing cap Allow pressure to escape before completely removing cap WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biol
15. M3AHOJSNVMI ONIZINONHONAS 2 WOHJ YIMOd Sl 53413238 Od SI ONIGI3M 104100 IHU 5 uN388n9 1 dinO 51081 2 ONY SONIGNIM MIM NOIVM3N3JO OV NONA INdINO ONITTAM 20 53200084 104100 IHL 280 5 405 530010 dO ONUSISNOD 85 104100 OL 830449 SI HOIHM 3SVHd OL 3SvHd Ov SITOA 09 AJilVWiXOSddV 3910054 SONIONIM 27 HONO BHE v S310V14323M 01 H34Od 3SVHd TIONIS SITOA OFZ 021 Ol ASN 51 9NIQNUM NOUVIIOX3 30 3SVHd 51104 099 AT3IVWIXOUddY 51 SHOLIOVdvO NO 3svHd Ol 3SYHd SHI SONIONIM 3SVHd Y JHL OL Q3103NNOO 210 LLO AB 31 3 7135 SI f 1 31 JO ul Lud Te Jw jor Te j f 22 1 M3AHOJSNVHL ONIZINOBHONAS 84 04 PAS 1081409 OL 48465 IWNINYAL zai E i o gavog D d HOLMS 55 1 1081409 301071402 1041 HOLMS 25 HOLMS 3ONVY 15 2 UUIANOUNELOd 30803 5 5 5 68 E Y er 5 30151533 3ONVY iNnHS YALIN N 7 ANAS 1980333 9u 2 L r L LLYM SZ OS 4015533 0 01383 LLIZISIZIS t S SWHO OS 53
16. approuv es Des crans lat raux BRUIT PEUTENDOMMAGERL OUIE 3 Entourez l aire de soudage de rideaux ou de cloisons pour L arc de soudage produit une chaleur et des prot ger les autres des coups d arc ou de l blouissement rayons ultraviolets intenses susceptibles de avertissez les observateurs de ne pas regarder l arc br ler les yeux et la peau Le bruit caus par 4 Portez des v tements en mat riaux ignifuges et durables laine certains proc d s peut endommager l ouie et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 2 1 PRECAUTIONS SECURITE SOUDAGE Instruction 830002 SELECTION DES NUANCES FILTRES OCULAIRES POUR LA PROTECTION DES YEUX COUPAGE SOUDAGE selon AWS 8 2 73 Op ration de Coupage ou soudage Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage avec electrode enrob es SMAW Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux m taux ferreux Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage avec lectrode de carbone CAW Soudage l arc Plasma Gougeage avec lectrode de carbone mince pais Coupage l arc Plasma PAC minc
17. 65 Ni mM ERN E mese rw SENN NOU YSC VL e a 886 12 14 Wd Wwe 00 1 0 NOU YNVTJX3 WVEOVIT 3005 0705 ms va comme wir ESTAS QOFO Wvusvig ew Tua GRO d 30587 803 830 MOTS CNT SOON me mam 340345 3SUQDHIO SSTINA 00 19350009 me awam INON 100008 3002 Say Zt W3dWnr 55748 330 v3u8 6 81 PTS i uise s v t 2 ie 9 9 9 9 w 1 3NION3 QN3 8 z MO1VH3N39 570008 ja Z 11395 96 12 7 va 4 7 NOHO3NNOO Jus NT 00608 SDWd CLES WXOGA e on uw 034035 89 12 1 0008 morum m ww mm JINON 100008 534 3002 E E 11 il E l E SONIONIM
18. 800021 800042 490594 C 31 800023 5 800023 7 800023 2 800023 1 10 800023 11 11 800023 6 12 800023 3 DAR August 24 1998 Parts List for Figure 8 2 Description Generator Assembly Cover Hole Housing Housing Flywheel Coupling Assembly Fan Coupling Key Coupling Armature Assembly Bearing Snap Ring O Ring Cover Upper Stator Housing Gen Assembly Screw Fan Cooling Fan Generator Cover Lower Stator 430429 427 PARTS LIST Qty per Assy 1 1 1 1 1 1 1 1 1 1 1 1 1 8 5 430429 427 PARTS LIST Figure 8 3 8 6 August 24 1998 Quantity Class 1 Class 2 August 24 1998 Number OQ N Part 492364 3 409158 405089 406000 494445 494130 494133 DDW 495 8 407366 359699 1 406187 406927 W 10869 3 406945 491414 494127 494135 1 494139 1 492191 1 491820 1 492195 406358 2 494456 1 402037 11 482367 1 492366 W 10931 3 405140 1 492413 405826 16DA 954 12 494459 1 410223 6 494459 8 494459 2 492533 6 Not Illustrated Parts List for Figure 8 3 Description Top Canopy Label Danger Label Fuel Label Warning Fuel Label Precautionary Shield Safety Cap Fuel Tank Cap Rain Label Brace Canopy Bracket Mtg Air Cleaner Cleaner Air Clamp Hose Hose Air Cleaner Reactor Stability Assembly Tank F
19. Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otezl lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apres le soudage Portez des v tements protecteurs non huileux tels d s gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de soudage 5 N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords congus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat 6 Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation 8 Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi q
20. Radiator Top Shroud Fan Hose Radiator Bottom Guard Fan Label Caution Brace Guard Block Drain Cable Batt Pos Cable Batt Neg Clamp Battery Rods Battery Angle Mtg Front Panel Frame Mounting Bar Mtg Gen Mount Shock Washer Shock Panel Side Left Battery Protector Batt Term Clamp Throttle Rod Guard Alternator Tray Capacitor Capacitors 60 uF Capacitors 70 uF N Q 00 N N A 8 9 430429 427 PARTS LIST Figure 8 4 Fuel Lines and Speed Control 8 10 August 24 1998 430429 427 PARTS LIST Parts List for Figure 8 4 Quantity Recomm Item Part Description Qty Spares No Number per Class 1 Class2 Assy 492288 1 Line Fuel amp Return 1 1 490036 Line Fuel 1 2 W 10869 14 Clamp Hose 6 3 355325 10 Hose Rubber 1 4 355325 16 Hose Rubber 1 5 405091 1 Elbow Male Barbed 1 6 402265 Valve 1 4 Turn Shut Off 1 7 492075 Line Return 1 8 491889 4 1 9 402927 1 Adapter Tube to Pipe 1 9A 12CW 2125 Elbow Street 45 1 Speed Control Section 10 490186 Arm Fuel Shut Off 1 11 400562 32 Spring 1 12 490028 Pivot Throttle 2 13 16DW 34 Bushing Throttle 2 14 494541 Clamp Throttle Rod 1 15 490010 1 Support Throttle Rod 1 16 492360 1 Bracket Spring 1 17 W 799F 110 Spring 1 4
21. Water condenses and collects quickly mixes with the oil and increases deposits to form a sludge Check oil frequently for this condition Water in crankcase or oil lines may freeze and cause August 24 1998 5 3 430429 427 OPERATION serious damage to the oil pump or shut off the oil supply e Battery Battery efficiency decreases sharply with lower temperatures Maintain the gravity of the battery between 1 275 and 1 300 fully charged condition Make sure of full charge before attempting to start engine in sub zero condi tions Operation In Hot And Humid Conditions a Cooling System Elevate welding machine 6 to 8 inches 150 to 200 mm above floor or ground level to provide adequate circulation of air Maintain a more frequent check of the coolant level in the radiator b Battery The specific gravity and proper level ofthe battery electrolyte should be maintained Observe recommendations in the Maintenance and Operators Engine Manual for proper care of the battery Operation In Extremely Dusty Conditions unit is to be operated under dusty out of door con ditions place in a sheltered area Take advantage of any natural barriers which may offer protection from blowing dust If the installation is more than tempo rary erect a protection shield a Fuel System Drain the fuel water trap sedi ment bowl frequently and keep all fuel containers covered and protecte
22. electric light bulbs to effectively dry out the windings If dampness is excessive apply external heat under a canvas cover well vented Heating should not exceed 194 F 90 C Pound out any dents in the canopy Sand prime or repaint any dented or rusted spots Lubrication Engine Consult Perkins Handbook for Diesel Engines 430429 427 MAINTENANCE This page intentionally left blank 6 2 August 24 1998 430429 427 TROUBLESHOOTING TROUBLESHOOTING The following chart contains information which can be used to diagnose and correct unsatisfactory opera tion or failure of the various components of the welding generator Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem Troubleshooting Guide No output at 115 V and 230 V Receptacles or Welding Terminals Unit won t build up voltage Loose connections Check connections completely Broken wiring Repair No output at welding terminals 115 V and 230 V receptacle output OK Shorted power diode SCR or flyback diode in output rectifier assembly Replace defective device Fuses to control P C Board blown Replace fuses Control P C Board failure Replace P C Board Output voltage too high Engine overspeeding Check engine RPM should read 1825 1840 no load Output voltage too low Engine running underspeed Check engine RPM Engine See Detroit Perkins Handbook For
23. engine Pull the control handle OUT all the way for engine to run at rated RPM 1800 Push the handle N against the panel to shut engine down Turn contro handle counterclockwise to loosen and clockwise to lock it in position Thermostart Pushbutton Place the starter Switch in position and hold the pushbutton N for 15 to 20 seconds prior to placing the starter switch in START position Continue to hold it N until engine fires 3 2 August 24 1998 CAUTION Do not hold the pushbutton for any longer period of time than the 20 seconds above engine does not Start first time place starter switch in OFF position then repeat above proce dure Oil Pressure Light Glows red when oil pressure drops to 3 5 psi for any reason Alternator Light Glows when engine alternator circuit is not charging the battery at sufficient level Fuel Gauge Indicates level of fuel in fuel tank Hour Meter Indicates run time on engine Water Temp Gauge Indicates coolant tempera ture Generator Controls Range Selector Switch This toggle switch is used to select either the low or high welding range as indicated on the Current Control Current Control The welding current control is located in the center of the control box door panel Turning knob clockwise will increase welding cur rent counterclockwise will decrease current Voltmeter Optional Indicates open circuit and we
24. received by the SCR gate circuit open and a very small change will occur at the welding arc and will be difficult to detect by the average welding operator Generally when this hap pens it will be necessary to adjust the current con trol onthe front ofthe power source see Figure 3 1 increasing the current to obtain the same welding current that was being produced before the SCR defect occurred Open Circuit Voltage Test Ifthe power source is suspected a very simple test can tell you a great deal about the power source Observe the open circuit voltage of the machine by placing a voltmeter across the output terminals The voltage reading should be approximately 75 V DC If the voltage is not equal or close to 75 V DC there is something wrong with the power source welding machine Note that this voltage was observed at normal engine speed 1800 RPM It will vary ac cording to the engine speed If the 75 V DC is observed there is a very good chance that the power source is operating properly NOTE Itis important to note that in the LOW range 15 to 200 amperes at minimum setting ofthe Current Control the open cir cuit voltage will drop to a lower value and vary slightly with the current control This is not a malfunction but a normal situation Power Diode And SCR Testing In case of a severe malfunction such as a shorted SCR do NOTturn the unit ON Disconnect the leads from the generator to the rectifier assemb
25. which will aid in preventing wet stacking 1 Open the fuel shut off valve at fuel tank 2 Start the engine see instructions under Engine Controls and Instruments included in Description of Equipment chapter and let it idle for a few minutes to warm up lubricating oil and coolant and then shut the engine off NOTE Idling RPM is approximately 1300 3 Check engine for low oil pressure leaks or malfunctioning parts If oil pressure does not show a sufficient steady pressure within 5 seconds shut engine down and determine cause 4 Start engine again Pull throttle control handle all the way OUT Operate unit with canopy doors closed NOTE Covering the radiator partially with cardboard or plywood during this operat ing period will speed up the engine warm up Care must be taken however to avoid overheating and boiling the coolant in the radiator 5 Apply a load to the welding generator This can be accomplished by attaching a proper resistance load across the welding terminals and setting the current control The load should be equal to at least one half of the normal full load output of the unit rated 300 amps 40 volts 6 Operate the engine generator unit for approxi mately one hour under the above loading condi tions NOTE This procedure can be followed at any time that wet stacking becomes a problem in order to burn out the unburned hydrocarbons that accumulate in the ex haust stack Pr
26. 0151538 88 5 ru zal T 7 En 190 140 iN Nid 9 IONSHANY 310v1d303N gn I 25 13300 cer Pu d gt 310N3H YaMOd XnV ASIL Set S GLIINNOD 08908 LINDMIO 1 1 I 53504 QuvOS 84 43 9 9 9 NOS ef ac oe 30010 83804 89782 dAVSL 785 10HLNO9 197 10 550109999 NOISS3Mdd S 3SION 907 SMaLlOVdvO 5 943931 2 1 x s 8 n 8 5 oL 1L zi YSN SEEDY 30 1 Did S80008 0 554 R ELD 14m yo nosy 05 889 fo aooo sum 70 ZZ 09 12 2 SNS 27655 Dd JAM ou 55 esame mesa mme Porn Guim ate noue 88 DEN 3123536 HER MJB8M N NOLYIO1 Osa QN 39vig 2
27. 166 9 22 405129 1 23 367579 405157 491454 1 24 491446 1 25 406040 26 405365 1 27 367703 1 28 406926 1 29 492576 30 402663 31 406806 3 32 491773 3 33 8BW 106A 34 402682 35 400758 36 404875 37 494097 1 38 DW 4333 August 24 1998 Not Illustrated Parts List for Figure 8 1 Description Light Snap Mt Red Deleted Plug Hole Plastic Switch Pushbutton Gauge Fuel Switch Toggle DPDT MOM ON Cover Hole Meter Receptacle Duplex 3 Wire 115 V Circuit Breaker Thermal Box Control Assembly Box Control Strip Terminal Q C 12 Station Strip Terminal Q C 6 Station Spacer P C Board Board P C Control Assembly Fuse 1 Amp Fast Blow Block Fuse Insulator Fuse Block Label Fuse Door Control Box Assembly Door Assembly Boot Toggle Switch Switch Toggle SPST Resistor 1 2 Watt Assembly Potentiometer 2 Watt 5 Board Mtg Pot Nut Pot Lock Knob Control Knob Control Spacer Switch Toggle Receptacle 6 Pin Amphenol amp Chain Assembly Panel Rear Lower Rod Throttle 430429 427 PARTS LIST Qty per Assy A N c N N 9o 0 0 WwW N 430429 427 Quantity Recomm Item Part Spares No Number Class 1 Class2 800023 491758 3
28. 1932 0 Block Drain 1 86 492133 4 Cable Batt Pos 1 87 492132 3 Cable Batt Neg 1 88 491962 2 Clamp Battery 1 89 494295 Rods Battery 2 90 491122 1 Angle Mtg Front Panel 2 91 800022 Frame Mounting 1 92 491683 2 Bar Mtg Gen 1 93 406254 3 Mount Shock 4 94 491799 1 Washer Shock 8 95 494129 1 Panel Side Left 1 96 402086 2 Battery 1 493797 2 Protector Batt Term 1 357013 Clamp Throttle Rod 1 97 494730 Guard Alternator 1 98 800031 Tray Capacitor 1 99 800023 10 Capacitors 60 uF 5 100 800023 9 Capacitors 70 uF 2 101 800023 12 Transfomer Bracket 1 102 800023 13 Synchronizing Transformer 1 February 21 2000 430429 427 ADDENDUM ADDENDUM DIAGRAMS Note the model and specification number shown on the equipment nameplate Locate these numbers in the model and specification number columns below e Use only those diagrams and instructions that are applicable MODEL SPECIFICATION CONNECTION CONTROL BOX ENGINE NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM Mega Arc 4030D 6298E 1 800085 494699 800085 Built after Refer to Diagram January 1 2000 Section in main manual February 21 2000 L 2 5 MISERE ETES MAT mr XS 1 1431 BO OBY s
29. 2 22 ELM WYHOVIG 3009 40109 NOUO3NNOO HVYOVIO Tu SENS HERE 1 4 1570 Wor Aun veau 40395 ISUANGHIO_SSIINO yanu ois rae 2 Es TIMIA Sv 3100008 Wid 3002 HSINIi 003 dois L OL 82 LINDYID GHLIINNOISIO 8 _ re 9 UNDC greg 30185 5 LHHOVYE Es ANOLOV ied LJ 8 5 Homo N L Saca gIONTIOS 555 mm EU FT 59 Ape NS 35 OdinHs 27 1 s cus d uis MT 2 18416 BAHIA WNOLdO Qi 4 l doi _1010 _ 334 NatvM Sd 30 305 WONJ Q3MGU 310 VNOUdO 9 i 8 NMOGEAHS 3NION3 TVNOLLdO MOLYNUALY p 6 4 rogi oti 5 1 6 TVISNI IR o SI M3I3AWV ioe 9 G3123NNOOSI SI JAM SIHL G 9 I 51 8 72 x8 0 5 3onvo aanas d iOS COR UB Mou xe E PUN 5 39715533 55484 iO L I AC MOT 4 34 SS3Ud WO 7 5310915
30. 90073 1 1 Not Illustrated August 24 1998 8 11 430429 427 PARTS LIST This page intentionally left blank 8 12 August 24 1998 EAST PENN manufacturing co inc Material Safety Data Sheet BATTERY FLUID ACID 8 UN2796 PGII Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station PA 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside continental U S call 1 202 483 7616 OSHA PEL ACGIH TLV 1 00 mg m Hazardous Components Specific Chemical Identity Common Name s Other Limits Recommended Percent Appearance and Odor clear odorless colorless Solubility in Water completely Boiling Point approximately 235 F Specific Gravity H 0 1 1 220 1 325 Evaporation Rate Butyl Acetate 1 less than 1 0 Vapor Density AIR 1 N A Melting Point N A Vapor Pressure mm Hg 13 Flash Point Method Used non flammable Flammable Limits N A Extinguishing Media N A LEL UEL Special Fire Fighting Procedures Sulfuric acid will not burn but is capable of igniting finely combustible material on contact Combustibles may be smothered by dry chemical extinguishing media Stability Stable Condition to Avoid Contact with metal may release explosive hydrogen gas Inc
31. Diesel Engines August 24 1998 7 1 430429 427 TROUBLESHOOTING Detailed Troubleshooting Instructions The Mega Arc 4030D machines are solid state welding machines The method of troubleshooting is different but it is not more difficult than trou bleshooting a conventional unit Do notoverlookthe obvious As in the case of all electrical equipment loose connections are the primary cause of mal function both internal and external to the power source Do not overlook bad grounds shorted con trol cables wrong settings blown fuses miscon nections from auxiliary equipment misapplications etc The only equipment needed to properly detect a problem on this power source is a simple vol tohmmeter although an oscilloscope is the best method to quickly see the problem Voltages Refer to proper connection diagram See Diagram chapter included in this manual Thefollowing voltages should be read at 1800 RPM engine speed 1 Welding circuit phase to phase on all three phases 60 V AC 10 2 Check for blown fuses F3 F8 Refer to Connec tion Diagram Between wires 13 brown 14 orange 15 grey 16 black 17 yellow and 18 blue on fuse block 60 V AC 10 NOTE The 10 value indicates the pos sibility of having a high orlow engine RPM Malfunction In SCRs Or Diodes The following conditions will probably exist 1 One SCR does not turn on either it is open or gate signal is not being
32. E VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT iS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS Except with regards to the products listed below this warranty shall remain effective three 3 years from the date Thermal Arc s authorized distributor delivers the product to Purchaser but in no event more than 4 years from the date Thermal Arc delivers the product to the authorized distributor Shorter warranty periods apply to the products listed below On these products the warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor ALL OTHER P WEE PRO LITE POWER SUPPLIES POWER SUPPLIES PRO PLUS PRO WAVE LABOR MAIN POWER MAGNETICS STATIC amp ROTATING 3 YEARS 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOID PUMPS POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRAN
33. ELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUC TION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven equipment Safe practices are outlined in the American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING This publication and other gu des to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is o
34. EN ET D ESSAI Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plon ger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode 8 N utilisez pas de c bles lectriques us s endommag s piss s ou de section trop petite N enroulez pas de c bles lectriques autour de votre corps N utilisez qu une bonne prise de masse pour la mise la terre de la pi ce souder Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 12 N utilisez que des quipements en bon tat R parez ou rem L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler grave ment L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimenta tion et les circuits internes de l quipement sont aussi sous tension d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pi ces m talliques en contact avec le fil de soudage 9 sont sous tension Un quipement ina
35. ES ET LES PROJEC TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec soin 1 Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage 2 Enchainez verticalement les bouteilles a un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es 3 Eloignez les bouteilles de tout circuit lectrique ou de tout soudage MISE EN GARDE LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN IN CENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein Instruction 830002 M fiez vous des projections brulantes de soudage suscep tibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur a port e de main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril
36. Light Under 1 8 in 4075 Carbon arc air gouging Medium 1 8 to 1 2 in 3 12 mm 5or6 Light Heavy 1 2 12 6 or 8 Heavy Shielded metal arc welding Under 5 32 4 10 Plasma arc cutting stick electrodes 5 32 to 1 4 in 410 6 4 12 Light Under 300 Amp Over 1 4 in 6 4 mm 14 Medium 300 to 400 Amp Over 400 Amp Gas tungsten arc welding TIG Atomic hydrogen welding All Carbon arc welding Al May 8 1996 2 1 WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases Kf ventilation is poor use an approved air supplied respirator WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot work piece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all
37. Make sure that no loose bars tools parts etc are in or on any part of the engine as they could August 24 1998 5 1 430429 427 cause serious damage to the engine generator personal injury to anyone standing nearby 5 If the unit is operated indoors make sure that an exhaust line is properly connected to the engine exhaust system and discharges out of doors Avoid short bends or reduction in line size in exhaust pipes and locate the unit so as to necessitate the shortest possible exhaust line to insure the least amount of back pressure on the engine Back pres sure can cause engine damage and loss of power 6 Attach welding leads as described under Initial Preparation For Use located in Installation chapter Observe Table 4 1 and determine that welding leads are proper size for amperage being used for weld ing Break in Procedures A proper break in procedure for a new diesel en gine driven welding generator is extremely impor tant to avoid future problems Long periods of operation at idle or light load condition may result in cylinder wall glazing and resultant poor seating of piston rings so that oil consumption will be exces sive Also it may result in wet stacking which is unburned fuel that accumulates in the exhaust pipe due to extremely low exhaust temperatures The following procedure will apply a load to the engine assuring the hot exhaust at least 450 F 232 C
38. OUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES O LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 249 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez connaitre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETI
39. SITIVE terminal Attach the WORK lead with clamp on end to the NEGATIVE terminal CAUTION Do not change welding leads while generator is running as open cir cuit voltage 80 volts is furnished to the terminals Shut engine down to change leads 11 Make sure that no loose bars tools parts etc are in or on any part of engine as they could cause 4 2 August 24 1998 serious damage to wreckage of engine ator or personal injury to anyone standing nearby 12 Carefully read and follow Operating Instruc tions in your engine operators manual Welding Leads Table 4 1 shows welding lead sizes recommended for various lengths of leads The footage shown includes complete welding circuit both electrode and work leads 430429 427 INSTALLATION TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS Welding ELECTRODE LEAD PLUS WORK LEAD Current 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet Amperes 15 2 M 30 5 45 7 61 0 76 2 100 4 4 2 1 1 150 2 2 1 1 0 2 0 200 1 1 1 0 2 0 3 0 250 1 0 1 0 2 0 3 0 4 0 300 2 0 2 0 3 0 4 0 2 2 0 350 3 0 3 0 3 0 2 2 0 2 3 0 400 4 0 4 0 4 0 2 2 0 2 3 0 NOTE Cable size shown is for 90 C 194 F cable insulation 30 C 86 F ambient and not over 4 5 volts cable drop August 24 1998 Table 4 1 Suggested Copper Welding Lea
40. Sl RS 1NVISOWH3HL 106 6 f Siam 1 Q3TWISN St JANIS g om lg SOE aus JAHLI N3HM 331055354 10 z ANNODSI 38 ISPA z lo Saez B si t 38 92 at 5 9 V ot ot a 8 Onus 1 I 3 lm P 1 LA tft l LL HOLMS m m ARS Zoe R 8 3unive3dWil Ko tH t et STE ye te D HON 951 N313WOHOVL le lavi 81 702 B 38065384 WO MOLVNYALW X8 9 Unam 3NISN3 TVNOLLdO M 11715 8 9820 xg 811 I N L VND 3onvo 1303 Le 4 ei Od 8 Ud Vi NOLI23NNOO 30010 580008 30 Kusdoid puo ssnpxe 133HS ON yo sny 00 12 6 37755 OG S080934 wwig 000 y y 00 12 2 5303538 wayo 00 08 00 380530 OUVW3HOS 3NION3 VIVO 3ALdfHOS30 EXE 00809 NOLO3NNOO Wwuovig Sr STWONVIS 412 90338 01 03200084 SN SisVd 6349530 YOONA 9345 waruvm 04 1439 3 AlddY MOTIE 53997701 B SYALIATIN SIHONI N SNOISN3 00 ON 031319395 5 531 00 12 2 5680008
41. TED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT 1 YEAR 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes ail previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc Thermal Arc Inc Effective January 4 1999 Troy Ohio 45373 830538
42. a aanu 395 03142345 3SUMAGHIO SSTINN dd 00 08 2 55970009 3101 WON3 Sv queen an 5 INON 100009 834 3009 HSIN DA 233 2 aa sous Fe c vase 391 1 d3123NNO9SIQ ca iit e 8 v FHM Q3TW1SNI q ANOLOVA d LANOVA 130 1SNIVOV NO 3dlS SIHL CON i 9 __ 58 4 NMOGLNHS ams 77 Lj aT 7 E 10 HOLIMS aay 4 LAVAS N3H13 1 0 1 2 dol L MS TOUINOD 43385 HOLIMS 3NION3 JO 3015 Q3MGIA 310 TVNOUdO 9 B NMOGInHS INION3 TVNOLLdO O 8 5 NOLLO3IONd 3 b 2 38 SZ 5 DOA ZL 5 1 x 15 AINE 00 t 51 MJI3AWY ANALYSE PA oi 93123440050 SI SIMI NE 166 9 G _ x8 52 0 T M3ON3S INAYO 1373 T 330435 HOLIMS DIONTIOS 4
43. are underlined they are ail cov ered by this manual Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily rec ognized as follows WARNING gives information re garding possible personal in jury Warnings will be enclosed in a box such as this CAUTION refers to possible equipment damage Cautions will be shown in bold type NOTE offers helpful information concern ing certain operating procedures Notes will be shown in italics Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be at tached to the rear panel Equipment which does not have a control panel such as gun and cable assem blies are identified only by the specification or part number printed on the shipping container Record these numbers for future reference 430429 427 INTRODUCTION Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due shipping Ifthere is any damage notify the carrier immediately to file a claim Furnish complete information con cerning damage claims or shipping errors to Thermal Arc Order Department 2200 Corporate Drive Tro
44. ce or total functional failure is to be avoided Consult Engine Workshop Manual and rec ommendations below a Fuel System Keep system clean and free from water which may collect in alow spot in the fuel line and freeze plugging the line Fuel tanks should be kept FULL to prevent water condensation from the air above the fuel Check the filter bowl daily for presence of water b Fuel Keep fuel storage tanks or drums as full as possible to avoid condensation of moisture from the air above the fuel After filling or moving fuel containers allow fuel to settle before using Never draw fuel from the extreme bottom of the container Strain all fuel to remove any foreign matter When operating outdoors take steps to prevent the entry of snow water and ice into the fuel containers Cooling System Prior to cold weather drain ad flush the cooling system to remove accumula tions of rust and sediment Mix and add antifreeze solution check the cooling system connections for leaks Add a can of rust inhibitor to the radiator when system is winterized This will keep system cleaner and furnish lubrication for the water pump d Lubrication Drain the crankcase prefer ably when warm after running and fill with a lighter grade ofoil See Engine Cil Recommendations chart in the Maintenance and Operator 5 Manual for rec ommended viscosity oil for various atmospheric temperatures In cold weather drain oil more fre quently
45. d quatement 10 install ou inad quatement mis la terre est dangereux 1 Ne touchez pas des pi ces sous tension 11 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et dela mise la terre au moyen de tapis isolants ou autres placez aussit t les pi ces endommag es D connectez la prise d alimentation de l quipement ou arr tez 13 Dans des espaces confin s ou mouill s n utilisez pas de source le moteur avant de l installer ou d en faire l entretien Bloquez le de courant alternatif moins qu il soit muni d un r ducteur de commutateur en circuit ouvert ou enlevez les fusibles de tali tension Utilisez plut t une source de courant continu mentation afin d viter une mise en marche accidentelle 14 Portez un harnais de s curit si vous travaillez en hauteur Veuillez installer cet quipement et le mettre la terre selon 15 Fermez solidement tous les panneaux et les capots le manuel d utilisation et les codes nationaux provinciaux et locaux applicables LE RAYONNEMENT DE L ARC PEUT 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apr s 8 V 96 pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure BR LER LES YEUX ET LA PE AU LE 2 ae 34 s curit
46. d Size Guide 4 3 430429 427 INSTALLATION This page intentionally left blank 4 4 August 24 1998 WARNING MA 4030D mounted on a trailer may develop a rough running low idle Normal idle speed is around 1300 RPM When mounted on some trailers the unit will interact with the trailer leaf springs and tires and cause it to run rough To eliminate adjust the idle screw on the injection pump see Figure 5 1 by turning either clockwise or counterclockwise to raise or lower the low idle speed Be sure however not to adjust the low idle below 1000 RPM as the generator will not operate properly 430429 427 OPERATION Figure 5 1 Prestarting Instructions In all probability the welding unit will be moved from one location to another many times during its lifetime of service Therefore reference to Initial Preparation For Use located in Installation chapter is suggested each time the unit is moved prior to using it 1 Check the supply of fuel crankcase oil and radiator coolant See Perkins Engine Handbook for specifications 2 Inspect the unit thoroughly to be sure it is in proper working order Check all fuel line and wire connections to be certain they are secure Tighten any loose screws nuts or bolts 3 Wipe off the entire unit and clean the air pas sages control box and hard to reach places with compressed air not over 25 psi 172 kPa 4
47. d against dust entry b Oil Filter and Air Cleaner These both need more frequent attention under dusty conditions Check air cleaner daily Replace oil filter cartridge as needed Change element in the air cleaner as required c Crankcase The crankcase oil level will bear close attention Dusty conditions tend to load crank case oil with dirt Watch for dirty and gritty oil con ditions and change oil more frequently as required Operation In Salt Water Areas a Canopy Wash canopy regularly to remove salt film Repaint any damaged places and oil the side panel hinges regularly b Covering To protect the engine and gener ator as much as possible from salt water atmos phere keep the side panels on the canopy closed when not in use It is advisable to keep the unit covered with a tarpaulin if available while not in operation Salt water should be wiped from the engine and all terminals and connections in the electrical system wiped dry Keep all linkage oiled c Brushes The brushes of the welding gener ator and exciter should be inspected regularly to make certain that they are free in the holders Liftthe brushes in the brushholders about every two days to insure their freedom to slide within the holder Wipe dry all the parts that can be reached and use compressed air if available to dry the parts of the generator that cannot otherwise be reached See Maintenance chapter for brush commuta
48. der is intended to be a base to held the welder components to gether This frame is not intended to be the primary structure of a trailer or wagon This welder is in tended to be installed on a rigid flat surface This surface must allow the weight of the welder to be distributed along the length of the welder frame Never install any vibration isolation material shock mounts etc beneath the welder frame This could defeat the engine generator shock mounts and cause abnormal vibration throughout the welder and produce vibration related problems Before choosing an installation location make note of where the service items are located on the welder oil change fill battery air filter fuel fill etc Install the welder for best access to the important service items Allow sufficient room for cooling air intake and exhaust if you are unsure about any installation consult the factory Trailer Installation Do not use the frame assem bly of this welder as the frame of a trailer do not attach axles or tongues directly to this frame Wnen a trailer is required use only trailers with its own support frame that has a gross weight rated to carry the weight of the welder and any other components mounted on the trailer Be sure the trailer tires are for use with trailers The soft sidewall design used in radial tires can cause vibration related problems Be sure welder frame and trailer frame are electrically bonded tog
49. e moyen pais Dimension d lectrode ou Epaisseur de m tal ou Intensit de courant toutes conditions moins de 1 po 25 mm de 1 6 po 25 150 mm plus de 6 po 150 mm moins de 1 8 po 3 mm de 1 8 1 2 po 12 mm plus de 1 2 12 moins 5 32 4 5 32 1 4 4 6 4 plus de 1 4 6 4 toutes conditions toutes conditions toutes conditions toutes conditions toutes conditions toutes dimensions moins de 300 amp res de 300 400 amp res plus de 400 amp res Nuance de de filtre oculaire LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer 1 Eloignez la t te des fum es pour viter de les respirer 2 A l int rieur assurez vous que l aire de soudage est bien ven til e ou que les fum es et les vapeurs sont aspir es l arc 3 Si la ventilation est inadequate portez un respirateur adduc tion d air approuv 4 Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev te ments et aux produits nettoyants 5 Ne travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protec teurs de soudage peuvent d placer de l air et ainsi causer des malaises ou la mort A
50. erm to Reactor Door Side Plate Hinge Hinge Door Latch Door Spacer Latch Handle Door Latch Muffler Engine Diesel Nipple Pipe Tee Pipe 1 8 Switch Oil Pressure Switch Cil Pressure Spacer Fan Support Engine Spacer Mtg Engine Label Oil Filter Panel Side Right Rectifier Assembly Suppressor W Lugs Suppressor Surge Assembly Bracket Mtg Bus Bar Bar Bus Belt Fan cdit edo qa Uo s cerent as oom o ecol Ite ROC Cs August 24 1998 430429 427 PARTS LIST Parts List for Figure 8 3 Quantity Recomm Item Part Description Qty Spares No Number per Class 1 Class 2 Assy 67 68 69 70 71 72 73 74 15 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 406149 494181 W 9360 229 494149 2 No Number 491721 2 492362 3 491689 23 491690 2 406981 1 406989 W 10869 12 406977 493252 2 405977 2 494741 406001 494725 5CW 1932 0 492133 4 492132 3 491962 2 494295 491122 1 800022 491683 2 406254 3 491799 1 494129 1 402086 2 493797 2 357013 494730 800031 800023 10 800023 9 Not Illustrated August 24 1998 Fan Engine Deleted Alternator Delco Cable Bonding Sender Water Temp Filter Fuel Supplied W Engine Bracket Mtg Fuel Filter Panel Front Plate Front End Support Radiator Radiator Cap Radiator Clamp Hose Hose
51. errosion and traceobronchitis Health Hazards Acute and Chronic Short term exposure Sulfuric acid may cause irritation of eyes nose and throat Prolonged contact may cause severe burns Long term exposure Repeated contact causes irritation and skin burns Repeated exposure to mist may cause errosicn of teeth chronic eye irritation and or chronic inflammation of the nose throat and bronchial tubes TARGET ORGAN respiratory system eyes skin amp teeth Emergency and First Aid Procedures 1 Flush contacted area with large amounts of water for at least 15 minutes Remove contaminated clothing and obtain medical attention 2 If swallowed give large volumes of water DO NOT induce vomiting obtain medical treatment Eyewash and shower stations should be made available Steps to be Taken in Case Material is Released or Spilled Dilute spill cautiously with five to six volumes of water and gradually neutralize with sodium bicarbonate soda ash or lime When exposure level is not known wear NIOSH approved positive pressure self contained breathing apparatus Reference DOT UN2796 Waste Disposal Method Neutralize and dispose in accordance with local state and federal regulations Precautions to be Taken in Handling and Storing Store away from reactive material as defined in Section V Reactivity Data Other Precautions Sodium bicarbonate soda ash sand or lime should be kept in same genera
52. ether Truck Bed Installation When installing this welder on the bed of a truck allow the welder to sit flat on the bed or a surface which completely con tacts the bottom of the welder frame Do not modify the welder frame by cutting or otherwise damaging it or the warranty may be voided Bolt the welder frame directly to the bed to secure it Do not install any vibration absorption device shock mounts etc between the welder and the truck bed Be sure welder frame and truck frame are electrically bonded together Ground Installation The welder will operate per fectly fine just sitting on the ground with or without August 24 1998 the shipping skid No special precautions are re quired Location For best operating characteristics and longest unit life take care in selecting an installation site Avoid locations exposed to high humidity dust high am bient temperature or corrosive fumes Moisture can condense on electrical components causing corro sion or shorting of circuits Dirt on components helps retain this moisture and also increases wear on moving parts Safety Refer to additional installation instructions under the Safety Warnings chapter included in this man ual Indoor Installation Adequate air circulation is needed at all times in order to assure proper operation Provide at least 24 inches 610 mm of space at radiator end of unit Make sure that ventilation openings are not ob s
53. eune Rd Miami FL 33126 P 1 from Compressed Gas Association 1235 Jefferson Davis High way Suite 501 Arlington VA 22202 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Code for Safety in Welding and Cutting CSA Standard W1 17 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Practices for Occupation and Educational Eye and Face Pro tection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Nationa Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 September 22 1999 Revised 2 3 WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 This page intentionally left blank 2 4 8 1996 PRECAUTIONS SECURITE SOUDAGE L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE AL ARC MISE GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ V
54. ewelding Instructions To adjust weld current and arc characteristics while welding the High Low Range Switch Current Control and Arc Force Control can all be adjusted under load without damaging the welding ma chine However caution should be used in switch ing from low to high range on the Range Selector Switch as this would cause the welding current to be immediately doubled This might be more than the electrode in use could stand This would cause immediate problems with the welding arc Note that on the Current Control dial the low range is just one half of the high range values For exam ple leaving the Current Control setting constant the high range would deliver 200 amperes and the low range 100 amperes This relation holds consistent through the entire range of the welding machine giving two widely overlapping current ranges The low range is 15 to 200 amperes and the high range is 30 to 400 amperes The entire usable range ofthe machine for stick electrode SMAW welding can be obtained in the single high range Adjustable Arc Force control for the welding proc ess gives the operator great flexibility in selecting the arc characteristics needed for a particular job Refer to Volt Amp Curves in Installation chapter Setting the Arc Force Control at 4 to 6 or in the FORCEFUL range will adjust the welding charac teristics of the machine to be normal and similar to many ofthe conventionally controlled engine drive
55. f contained unit mounted on a welded steel frame The unit is covered by a sheet metal canopy bolted directly to the frame The control panel is at the back generator end of the unit The generator is an asynchronous brushless self excited design The rotor assembly is supported on a heavy duty shaft by a single bearing at the rear and a flexible disc coupling at the engine flywheel The generator is a self excited design utilizing AC capacitors permanently connected to an excitation winding on the stator The welding circuit 3 phase wye connected rec tified to DC power by the output rectifier and stabi lized by the stability reactor The auxiliary power current provides 115 volt and 230 volt AC power to the receptacles on the Control Panel for operation of small tools lights etc See Tabulated Data for rated auxiliary power of your unit Engine The engine used in this unit is a Perkins Industrial 3 152 diesel engine It is directly coupled to the welding generator shaft by a flexible coupling Identification The welding generator unit has an identification plate attached to the control panel on the left hand side The unit is identified as to SPEC number by the dash number which follows it The engine identification number is stamped on right hand side ofthe cylinder block When ordering spare parts or communicating about this machine be sure to specify the engine serial number engine type unit specificatio
56. flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Bealertthat welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag CYLINDERS can explode if damaged Shielding gas cylinders contain gas underhigh pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat me chanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping amp WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 2 2 Read the Material Safety Data Sheets MSDSs and the manu facturer s instruction for metals consumables coatings and cleaners Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to
57. form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 5 Watch for fire and keep a fire extinguisher nearby 6 Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin Keep cylinders away from any welding or other electrical cir cuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition
58. happer avant d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI 749 1 American Weld ing Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 24 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Pro tection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 8 V 96 430429 427 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT Generator The diesel engine driven arc welding machine is a sel
59. l area for emergency use Respiratory Protection Specific Type Acid gas respirator required when PEL is exceeded or employee witnesses respiratory irritation See Section VI Health Hazard Data Ventilation When PEL is exceeded Mechanical general Local exhaust preferred Special Other Adequate ventilation to maintain exposure concentrations below the PEL Protective Gloves acid resistant for example rubber Eye Protection Mandatory during handling and transfer of acid recommend chemical goggles Other Protective Clothing or Equipment acid resistant aprons boots protective clothing and face shield Protective Gloves acid resistant for example rubber Work Hygienic Practices Good personal hygiene and work practices are mandatory DIAGRAMS 430429 427 DIAGRAMS e Note the model and specification number shown on the equipment nameplate e Locate these numbers in the model and specification number columns below Use only those diagrams and instructions that are applicable CONTROL MODEL SPECIFICATION CONNECTION BOX ENGINE NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM Mega Arc 4030D 6298E 1 800045 494699 800045 August 24 1998 z 1 970008 re E 01 q ama w ul TREER nas f 30 1 13365 ous 3 96 918 Svea Tvs
60. lding arc voltage when supplied Ammeter Optional Indicates welding current being used to weld when supplied Arc Force Ampere Control Varies the short cir cuit welding arc current and produces an increase of amperage when arc length is shortened Turning 430429 427 DESCRIPTION OF EQUIPMENT this control clockwise increases arc force counter clockwise decreases arc force See Operation chapter for details Welding Terminals See Figure 3 2 The two welding terminals are located on the Welding Output Panel which is located on the left hand side of the unit facing the control panel See instructions in Initial Preparation for Use located in the Installation chapter Auxiliary Power Receptacle Duplex receptacles located on the Control Panel see Figure 3 1 furnish 3 kVA 115 volt and 230 volt 60 Hz power NOTE The output voltage will drop below the rated volts when engine is in the idling mode Low voltage may damage electrical equipment connected to the generator through this receptacle Welding Terminals Figure 3 2 Weld Output Panel August 24 1998 430429 427 DESCRIPTION OF EQUIPMENT VOLT AMP CURVES MODEL MA 4030D TYPICAL WELDING VOLTS DC ARC FORCE SETIINGS WELDING AMPS DC Volt Ampere Curve 3 4 August 24 1998 430429 427 INSTALLATION INSTALLATION General Engine Driven Welder Installation The frame of an engine driven wel
61. ly and check with a for shorted SCRs and diodes An open gate or an open SCR cannot be checked with a VOM If an SCR is not firing the open circuit voltage will shift down Check the following table for typical values for a Mega Arc 4030D unit All Three SCRs One Not Two Not Not Firing Firing Firing Firing Max 75VDC 50VDC 25V DC OVDC Table 7 1 NOTE The above values in Table 7 1 were recorded at normal engine RPM 1800 Isolating Malfunctioning SCR This can be done best by trial and error method Use proper diagram as reference while inspecting the unit On the output rectifier heat sink there are three SCRs each having two small leads The leads white and red one are connected to a wire harness providing the gate signal to the SCRs Turn the Current Control to maximum position fully clockwise and begin disconnecting the white leads from the harness one at a time As the first lead is disconnected observe the open circuit volt age of the machine If the OCV drops to a lower value it wil indicate that this particular SCR is work ing properly Reconnect this lead and proceed to do the same with the remaining two leads until you discover which disconnection does not cause the to drop to a lower level This will be the SCR which should be changed 7 2 August 24 1998 Printed Circuit Board Testing The next step is t
62. m pressed on rectifiers in the alternator The resulting high current will damage rectifiers and or wiring harness 6 Fill fuel tank with grade of fuel recommended by engine manufacturer Consult engine instruction manual Be sure fuel is free of WATER and other foreign matter Make sure air vent to fuel tank is open See Safety Warnings chapter included in this manual for precautions necessary when filling the tank 7 Check to be sure that radiator is full about 1 below neck If not add enough coolant 50 50 mix of water and antifreeze to fill 8 Pull the dipstick and check the oil level in crank case If it is necessary to add oil fill to dipstick mark with correct seasonal grade of quality detergent oil See engine operator s manual for recommended viscosity and temperature chart unit is shipped with SAE 10W30 oil installed 9 After engine has been properly prepared for use start the engine and allow it to idle for 30 minutes or so Carefully check again for any leaks or loose connections during this period 10 Determine which welding polarity will be suit able for the welding job to be done a For STRAIGHT polarity DCEN attach ELEC TRODE lead leading to electrode holder to the NEGATIVE terminal on the Terminal and Recep tacle Panel Attach the WORK lead with clamp on end to POSITIVE terminal b For REVERSE polarity DCEP attach ELEC TRODE lead leading to electrode holder to the PO
63. n In semiautomatic or auto matic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or im properly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned on accidentally Properly install and ground this equipment according to its Owner s Manual and national state and local codes ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing Electrode Size Filter Welding or Cutting Metal Thickness Shade Operation or Welding Current No Torch soldering 2 Torch brazing 3or4 Oxygen cutting Gas metal arc welding MIG Turn off equipment when not in use Disconnect power to equipment if it will be left unattended or out of service Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time
64. n stick electrode welding machines However turning down the Arc Force Control to the 2 to 4 or SMOOTH range gives a softer less spatter type of welding arc Setting the Arc Force Control to DIGGING 6 to 10 range gives a very forceful driv 5 2 August 24 1998 430429 427 ing arc which makes sticking the electrode nearly impossible Note on the Volt Amp Curves that this adjustment of arc characteristics is accomplished by changing the short circuit to welding current ratios as indi cated by the dotted lines for arc force settings of 0 2 5 and 10 on the dial Welding After all Prestarting and Break In Procedures have been carried out the controls for using the gene ra tor for welding may be set and welding accom plished Follow this procedure 1 Start engine per aboveinstructions Operate unit with canopy doors c osed 2 Set Range Selector Switch on desired range and adjust current control for desired current Turning the current control clockwise increases the welding current and open circuit voltage while turning it counterclockwise decreases the welding current 3 Strike an arc and begin welding If a change in welding current is desired increase by turning knob clockwise until desired current is obtained See Prewelding Instructions above for details on current range current level and arc force control Stopping The Engine 1 Stop welding 2 Push the throttle c
65. n VI Health Hazards Lead Waste Disposal Method Lead acid batteries are completely recycable For information on returning batteries to East Penn for recycle call 610 682 6361 Other Precautions N A Respiratory Protection Specific Type For specific information see 29CFR 1910 1025 Lead Exposure Ventilation Local exhaust Mechanical general Special Other Protective Gloves N A Eye Protection N A Other Protective Clothing or Equipment N A Work Hygienic Practices Always practice good personal hygiene habits and safe work practices Shipping Name Battery dry Identification Number N A non assigned Hazard Class N A This article is not applicable to 49CFR 172 101 Hazardous Materials and not subject to Parts 170 189 of this sub chapter U S Postal Service Regulations unrestricted Material Safety Data Sheet BATTERY WET FILLED WITH ACID 8 UN2794 Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station PA 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside continental U S call 1 202 483 7616 Hazardous Components Specific Chemical Identity Other Limits Common 5 OSHA PEL ACGIH TLV Recommended Lead CAS 7439921 0 05 mg m 0 15 mg m Sulfuric Acid CAS 7664939 1 00 mg m 1 00 mg m mg m 0 50 mg m Antimony CAS 7440360 1
66. n and serial numbers Left and right hand sides of the unit are determined when facing the control panel See Supplementary Mate rials for address for communicating or ordering engine parts Tabulated Data Generator Output Auxiliary Power 115 230V AC Output Welding Generator 12 kW Amperes rated 300 Amps Voltage rated 40 Volts Voltage open circuit max 75 Volts Duty Cycle rated 100 Current Range Low Range 1510 200A High Range 30 to 400 Operating Speed See Engine Data Engine Make and model Sie de Detroit Diesel Perkins 3 152 Type Industrial diesel Displacement 152 cu in 2 50 liters Brake horsepower 38 BHP 1800 RPM Oil sump capacity 7 1 2 quarts 7 liters Cooling system capacity see cto 9 1 2 quarts 9 liters Fuel tank capacity 17 gallons U S 64 4 liters Weight dry 463 pounds 210 kg Normal operating RPM 1800 RPM Dimensions and Weight See Figure 4 1 Width doors closed 28 inches 711 mm Width doors open 77 inches 1956 mm Length 61 1 2 inches 1562 mm Height top of canopy era nS Ne ta 41 inches 1041 mm Height over eye in top CT 46 inches 1168 mm Weight shipping das approx 1700 pounds 765 kg A
67. nent de l lectrolyte acide et d gagent des vapeurs explosives LA VAPEUR ET LE LIQUIDE DE RE FROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression Seules des personnes qualifi es doivent d monter des protec teurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mou vement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudag un accumulateur ou survolter momentan men 5 Utilisez la polarit correcte et de l accumulateur e pour charger un v hicule N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour Laissez la pression s c
68. o check the Printed Circuit Board inside the unit See Figure 7 4 and Table 7 2 for location of test points and voltage values at the test points The following conditions indicate the possibility of a defective P C Board 1 Loss of welding arc completely 2 Rough sputtering arc very noticeable 3 Loss of welding arc control 4 Difficulty in starting arc If any voltage measurement does not agree with Table 7 2 voltage values the P C Board is probably defective NOTE Do not attempt to repair or recali brate these voltages as they are factory set Mounting Procedure for SCRs 1 Thoroughly clean heat sink surface to eliminate any dirt or contamination August 24 1998 430429 427 TROUBLESHOOTING 2 Apply a thin coat of Alcoa 2 compound to cleaned surface Alcoa 2 is available from Thermal Arc part number 903870 3 Positively locate the SCR in place in the heat sink A small spring pin in the extruded heat sink will locate the SCR 4 Place the clamp in position with the bolts through the holes in the heat sink and proceed in following manner 5 Tighten the nuts evenly until finger tight 6 Tighten each bolt in 1 4 turn increments using correct size hex key 7 Placethe Force Indicator Gauge 903878 firmly againstthe springs as shown Be sure both ends and the center are in firm contact with the springs The gauge notch location will indicate the spring deflec tion or force Correct mo
69. ogical Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 3 Do not coil or drape cables around the body 2 Arrange cables to one side and away from the operator 4 Keep welding power source and cables as far away from body as practical About Pacemakers The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard Z49 1 from American Safe Handling of Compressed Gases in Cylinders CGA Pamphlet Welding Society 550 N W LeJ
70. ompatibility Materials to Avoid Strong alkali materials carbides chlorates nitrates and pierates organic acid acetates anhydrites Hazardous Decomposition of By Products Thermal decomposition or combustion may produce a sulfur trioxide and or sulfur dioxide Hazardous Polymerization will not occur MSDS Battery Electric Storage Dry 2 2 Route s of Entry No applicable under normal use Health Hazards acute and chronic Internal components contain lead Repeated or prolonged exposure to lead can result in lead poisoning Lead accumulates in the bone and body organs and is eliminated from the body slowly Ref 29 CFR 1910 1025 Carcinogenicity N A IARC Monographs Group 2B carcinogen OSHA Regulated 29CFR1910 1025 Medical Conditions Generally Aggravated by Exposure Pregnant women and children must be protected from lead ex Signs and Symptoms of Exposure Short term Skin and eye irritation headache nausea vomiting abdominal spasms fatigue weight loss anemia pain in legs arms and joints Long term CNS damage kidney disfunctions and potential reproductive hazard Symptoms of lead exposure can be confirmed by the presence of elevated levels of lead in blood Emergency and First Aid Procedures Not applicable under normal use If lead exposure is suspected seek medical attention Steps to be Taken in Case Material is Released or Spilled Avoid contact with internal components See Sectio
71. ontrol handle IN towards the panel as far as it will go 3 Allow engine to cool sufficiently then check coolant and crankcase oil level If engine oil is to be changed it can be done most effectively while en gine is still warm CAUTION Use extreme care when re moving a radiator cap from an over heated engine Turn the cap only to the first notch and allow steam to escape before removing the cap completely 4 After engine has cooled completely fill the fuel tank See Safety Warnings chapter included in this manual for precautions that should be taken when filling the fuel tank Storage Nightly After operation the following steps should be taken before storing the welding machine for short periods of time 1 Clean up around working area Put all tools parts and supplies in their proper places 2 Disconnect welding leads from machine Coil them and stow away in their place 3 If unit is to be stored outdoors it is wise to cover it with a tarpaulin Extensive Storage Time If unit is to be laid up for some time please refer to Withdrawing An En gine From Service in Maintenance Section of Perkins Handbook for Diesel Engines which is sup plied with each unit Adverse Weather Precautions Cold Weather Operation Operation of engine driven welding units at sub zero temperatures re quires special precautions and extra servicing from both operation and maintenance personnel if poor performan
72. or touch other people with the holder or electrode Do not use worn damaged undersized or poorly spliced ca bles Do not wrap cables around your body Ground the workpiece to a good electrical earth ground Do not touch electrode while in contact with the work ground circuit Use only well maintained equipment Repair or replace dam aged parts at once In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output Wear a safety harness to prevent falling if working above floor level Keep all panels and covers securely in place Wear a welding helmet fitted with a proper shade of filter see ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high Electrode Size Welding or Cutting Metal Thickness Operation or Welding Current Non ferrous base metal Ferrous base metal Al Light Underiin 25mm 3or4 Medium 1t06in 25 150mm 40 5 Over 150 5076 Gas welding Plasma arc welding
73. reathing apparatus Reference UN2796 Waste Disposal Method Lead acid batteries are completely recyclable For information returning batteries to East Penn for recycling call 610 682 6361 Precautions to be Taken in Handling and Storing Store away from reactive material defined in Section V Reactivity Data Other Precautions Sodium bicarbonate soda ash sand or lime should be kept in same general area for emergency use See Section IV on generation of hydrogen gas If battery case is broken avoid direct contact with internal components Respiratory Protection Specific Type Acid gas respirator required when PEL is exceeded or employee witnesses respiratory irritation See Section VI Health Hazard Data Ventilation Must be provided when charging in an enclosed area 29CFR1910 178 g and 305 3 7 Mechanical general acceptable at 1 to 4 air exchanges hour or to maintain air concentrations below the PEL Local exhaust preferred Special Other local building fire codes may require explosion proof fans and equipment Protective Gloves acid resistant for example rubber Eye Protection preferred Other Protective Clothing or Equipment acid resistant aprons boots and protective clothing Work Hygienic Practices Good personal hygiene and work practices are mandatory EAST PENN manufacturing co inc A Material Safety Data Sheet BATTERY ELECTRIC STORAGE DRY Manufacturer s Name Date P
74. repared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station PA 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number 1 800 424 9300 In Washington D C or outside continental U S call 1 202 483 7616 Hazardous Components Specific Chemical Identity Other Limits Common Name s Recommended Appearance and Odor N A Solubility in Water N A Boiling Point N A Specific Gravity 0 1 N A Evaporation Rate Butyl Acetate 1 N A Vapor Density AIR 1 N A Melting Point N A Vapor Pressure mm Hg N A Flash Point Method Used N A Flammable Limits N A LEL N A Extinguishing Media Dry chemical carbon dioxide water spray or foam pecial Fire Fighting Procedures Unusual Fire and Explosi Stability Stable Conditions to Avoid N A Incompatibility Material to Avoid N A Hazardous Decomposition of By Products N A Hazardous Polymerization will not occur Page 1 of 2 MSDS Battery Fluid Acid 8 UN2796 page 2 2 Route s of Entry Inhalation skin contact and ingestion Carcinogenicity N A signs and Symptoms of Exposure Acid contact may cause irritation of eyes nose and throat Breathing of mist may produce respiratory difficulty Contact with eyes and skin causes irritation and skin burns Sulfuric acid is a CORROSIVE chemical Medical Conditions Generally Aggravated Exposure Pulmonary edema bronchitis emphysema dental
75. ssurez vous que l air est propre la respiration 6 Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants 7 Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que 51 l espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui con tient ces l ments peuvent d gager des fum es toxiques au moment du soudage 8 V 96 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC LE SOUDAGE PEUT CAUSER UN IN CENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes ie m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es LES ETINCELL
76. standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Therma Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal Arc shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract negligence strike tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY AR
77. stion Health Hazards Acute and Chronic Short term exposure Sulfuric acid may cause irritation of eyes nose and throat Prolonged contact may cause severe burns Long term exposure Repeated contact causes irritation and skin burns Repeated exposure to mist may cause errosion of teeth chronic eye irritation and or chronic inflammation of the nose throat and bronchial tubes TARGET ORGAN respiratory system eyes skin amp teeth Carcinogenicity N A Signs and Symptoms of Exposure Acid contact may cause irritation of eyes nose and throat Breathing of mist may produce respiratory difficulty Contact with eyes and skin causes irritation and skin burns Sulfuric acid is a CORROSIVE chemical Medical Conditions Generally Aggravated by Exposure Pulmonary edema bronchitis emphysema dental errosion and traceobronchitis Emergency and First Aid Procedures 1 Flush contacted area with large amounts of water for at least 15 minutes Remove contaminated clothing and obtain medical attention 2 If swallowed give large volumes of water DO NOT induce vomiting obtain medical treatment Eyewash and shower stations should be made available Steps to be Taken Case Material is Released or Spilled SULFURIC ACID Dilute spill cautiously with five to six volumes of water and gradually neutralize with sodium bicarbonate soda ash or lime When exposure level is not known wear NIOSH approved positive pressure self contained b
78. t is resting on an inclined surface or for other reasons Tie the doors to each other to lifting eye or fuel filler cap Failure to do so may result in injury to operating personnel 2 Inspect unit thoroughly to be sure it is in proper working order Check all fuel and wire connections to be certain they are secure Tighten any loose screws nuts or bolts Check closely for any dam age which may have occurred in transit 3 Remove all special tags from the machine read carefully and follow any special directions they may carry Keep tags with manual for future reference 4 Make certain that all radiator air passages and cooling fins are free from foreign matter Use clean dry compressed air to blow dirt and dust out of cooling passages and control cabinet 25 psi 172 kPa maximum pressure 5 Attach battery cables to poles of battery as indicated on wiring diagram The negative pole should be grounded to the frame of the unit in a secure manner WARNING Connect proper bat tery cable clamp to the positive battery post first then the other cable clamp to the nega tive post CAUTION A short circuit to rectifier is created if a battery is installed with po larity reversed Current can flow from positive terminal of battery through negative and positive rectifiers and into heat sink From heat sink a completed circuit exists back to negative battery terminal Full battery voltage will be i
79. tor care d Field Coils The fields should be dried as thoroughly as possible If they have become damp proceed with recommended procedure in Mainte nance chapter Battery Terminals Thoroughly clean the battery terminals and connections Coat terminals and connections with petroleum jelly to retard cor rosion 5 4 August 24 1998 MAINTENANCE Engine And Related Components NOTE Check Detroit Diesel Perkins Hand book for Diesel Engines for all engine re lated maintenance Inspection And Cleaning Every Day check for oil coolant or fuel leaks Also check for loose electrical connections Check oil pressure with engine running at rated RPM 1800 RPM Do not operate engine if oil pressure light stays ON Wipe accumulated water off all electrical connections and instruments Make sure that the alternator light is not glowing which indicates bat tery is being fully charged Every Week wipe accumulated dust dirt and oil off from the engine and generator Check all parts for looseness and wear If arcing has occurred at August 24 1998 430429 427 MAINTENANCE any electrical connection recondition it and se curely refasten Check engine oil and coolant levels Every Month blow out generator windings with compressed air not over 25 psi 172 kPa pressure or remove with a suction type cleaner with a non metallic nozzle If windings should become slightly damp use space heaters or
80. tructed Allow ample space to open canopy doors on sides of the unit see Tabulated Data in Descrip tion of Equipment chapter for dimensions for serv icing and space at the control panel end of unit for Operation If unit is to be operated inside a building make certain there is adequate ventilation to carry off escaping exhaust fumes and to provide an ample supply of oxygen Place unit so that exhaust fumes are carried out of the building using the shortest exhaust pipe possi ble and one with the fewest possible number of bends Exhaust back pressure can seriously affect engine efficiency All exhaust connections must be gastight Portable Installation For portable use the machine may be located within 12 inches 305 mm of a truck cab panel or whatever if it is to be operated in the open air The engine ofthe welding machine must be placed at the tongue end of the portable mounting for proper balance If leads etc are to be stored on 4 1 430429 427 INSTALLATION unit they must be forward the axle to maintain proper balance of loading on the tongue end of the unit NOTE The unit should be operated in as near a normal horizontal position as possi ble and never at a tilt greater than 10 side ways and or 7 maximum rear down Initial Preparation For Use 1 Open canopy doors on sides of engine CAUTION The canopy doors may fall to a closed position during operation of the unit if i
81. ty Liu de ANS Pen dicho dei de 4 1 ndoofinstallation xu Eus Lana RA Xon ELE 4 1 Portable Installation x en bea ste op Ru EU RES OS 4 1 Initial Preparation For Use 4 2 Welding beads 9 9 al qu Race diet ua S E Er 4 3 OPERATION 5 Prestarting Instructions 5 1 Break in Procedures 5 2 Prewelding Instructions 5 2 Welding Z7 eek US eh Ass 5 3 stopping The Engine ge AER CIDE IRE UE 5 3 Storages ns S M suit Steg Tan le i eb ed dpt tte d ios 5 3 Adverse Weather Precautions 5 3 MAINTENANCE 6 Engine And Related Components 6 1 Inspection And Cleaning 6 1 Lubrication uum 2 Roy d or a Y qe pus 6 1 August 24 1998 Page 1 430429 427 Table of Contents TROUBLESHOOTING PARTS LIST Equipment Identification How To Use This Parts List How To Select Recommended Spares MATERIAL SAFETY DATA SHEET DIAGRAMS ADDENDUM WARRANTY Page 2 February 21 2000 Revised INTRODUCTION How To Use This Manual This Owner s Manual usually applies to just the underlined specification or part numbers listed on the cover If none
82. ue la publica P 1 de la identifi e dans la liste de documents ci dessous LES MOTEURS PEUVENT ETRE DANGEREUX Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 PRECAUTIONS DE SECURITE SOUDAGE Instruction 830002 DES PIECES EN MOUVEMENT PEU VENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EX PLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contien
83. uel Sender Fue Gauge Support Fuel Tank Panel Heat Shield Support Heat Shield Cover Heat Shield Resistor Preload Yoke Lifting Assembly Grommet Lifting Yoke Plate Rect Output Right Plate Rect Output Left Rectifier Silicon Controlled Clamp Mounting Heat Sink SCR Rectifier Silicon Controlled Pin Spring Spacer Insulating Tubing Fiber Spacer Insulator Spacer Insulator Panel Terminal Assembly 430429 427 PARTS LIST Qty per Assy N N N N WO OR Naad gt gt N N N 430429 427 PARTS LIST Quantity Recomm Item Number Spares No Class 1 Class 2 63A 64 65 66 Part 492532 2 5CW 974 No Number 5CW 975 5CW 976A No Number No Number 351505 368705 7 No Number No Number 367687 W 9234 338 W 9234 339 491763 3 490174 490040 490234 493457 492244 406155 406080 W 10750 2 W 10910 0 402130 409159 494824 491673 2 491672 1 406178 494128 1 409554 1 202258 5 367634A 5 492049 492047 403618 7 Not Illustrated Parts List for Figure 8 3 Description Panel Output Weld Bar Bus Nut 1 2 13 HWH ST Bushing Insulator Washer Insulating Washer 1 2 FL ST Washer 1 2 LK ST Screw 1 2 13 x 1 3 4 Capacitor Assembly Screw 6 30 x 3 16 Rd Hd MH Washer 1 2 FL ST Shunt Cable Output Term to Rect Cable Output T
84. ugust 24 1998 3 1 430429 427 Range Selector Switch Voltrneter Optional Ammeter Optional Control Box Door Fuel Gauge Contactor Current Control Arc Force Ampere Control 10 Arme Circuit Breakers 9 9 5 15 Volt 2 250 Receptacle Current Control Switch Control Remote Switch Control Receptacie Throttle Igniti Hour gnition Thermostart Switch Pushbutton Ae er Water Meter Pressure 1g Temp ig Gauge 467 Figure 3 1 Control Panel Supplementary Materials NOTE Switch must be in OFF position to Acopy ofthe Perkins Handbook for Diesel Engines is included with each welding generator unit Addi tional copies may be obtained from the manufac turer Engine Controls and Instruments Ignition Switch The diesel engine starting motor is actuated by this switch located in the lower left hand corner of the control panel Do NOT crank the engine for more than 30 seconds at a time as this may cause the starting motor to overheat Allow motor to cool before attempting to start the engine again Place switch in START position to start and return to RUN position after the engine has started When engine is shut down place switch in OFF position avoid lighting the Alternator and Oil Pres sure light Throttle This control shuts the diesel fuel sup ply off for normal shutdown of the
85. uired for spares or replacement purposes The quantities under Class 1 are for parts that are consumed or that may need replace ment in two years or less depending on operating hours Class 2 quantities are for parts that may need replacement under unusual service condi tions or additional operating hours These are sug gested quantities based on expected usage or the minimum package quantity Class 1 spares are repeated under Class 2 but the quantities may be larger to allow for additional operating hours Con tact your equipment dealer for assistance in estab lishing the spare parts program best suited for your needs SPEC NUMBER 6298E 1 August 24 1998 8 1 430429 427 PARTS LIST Quantity Recomm Item Part Spares No Number Class 1 Class 2 494119 10 494096 1 404089 403091 4 403091 12 79C 1149 1 494150 1 D Q 8 2 Figure 8 1 Control Panel Parts List for Figure 8 1 Description Panel Control Assembly Panel Control Receptacle Duplex 3 Wire 230 V Plug Hole Plastic Plug Hole Plastic Meter Engine Hour Gauge Water Temp Qty per Assy August 24 1998 Quantity Recomm Item Part Spares No Number Class 1 Class 2 7 406004 1 8 9 403091 2 10 30GH 1119 11 494134 1 12 404856 13 405982 1 14 402670 15 409527 3 492010 8 16 492036 1 17 406003 2 18 406003 1 19 404915 1 20 491238 21 W 11
86. unting force is indicated as shown below 8 Spring deflection over 2 1 4 inches of spring is 037 002 for all clamps 9 All clamps to be set at 4 mark This corresponds to the VE3000 VE2500 section on the gauge label 7 3 430429 427 TROUBLESHOOTING Force Gage shown in position 903878 405140 H Figure 7 1 To Calibrate Force Gauge Examples Less than rated force Tighten nuts alternately 1 4 turn at a time until points coin cide Top edges lined up Correct rated force Figure 7 2 A 488 Excessive force Loosen both nuts and start over Never adjust force by back ing off the nuts Friction will produce a false reading Al ways start from Step 1 if the gauge is suspected of being out of calibration due to wear or damage check it on a flat surface as shown below ETS 227 LLL LLL LL True flat surface or straight edge ifthe calibration edges do line up calibrate the gauge by filing the bottom contact points Figure 7 3 7 4 August 24 1998 430429 427 TROUBLESHOOTING 15 1 A PI PER 7 5 J E 16 e
87. y Ohio 45373 1085 Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before uncrating the unit A lifting eye extends through the top of the cabinet on most equipment to facilitate handling with a hoist or crane Use care to avoid damaging the equipment when using bars ham mers etc to uncrate the unit WARNING Falling machine due to lifting eye failure may cause death or serious injury e Lifting device may fail when overloaded This lifting device is designed to lift the power source ONLY If the machine is equipped with a trailer or accessories over 100 pounds DO NOT LIFT by lifting eyes Avoid sudden jerks drops or swinging Check lifting device components visually for looseness and signs of metal fatigue e Before changing any hardware check grade and size of bolts and replace with bolts of equal or higher size and grade Additional copies ofthis manual may be purchased by contacting Thermal Arc at the address given above Include the Owners Manual number and equipment identification numbers August 24 1998 1 1 430429 427 INTRODUCTION This page intentionally left blank 1 2 August 24 1998 WELDING SAFETY INSTRUCTIONS WARNINGS instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING ARC WELDING can be hazardous PROTECT YOURS
88. y numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts parts ofthe equipment are listed except for commer cially available hardware bulk items such as wire cable sleeving tubing and permanently at tached items which are soldered riveted or welded to another part The part descriptions may be in dented to show part relationships To determine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item in the Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual How To Select Recommended Spares The first two columns of the Parts List are used to show the recommended quantity of parts which are typically req
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