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MEGA-ARC 4030D 30 Amp Constant Current Diesel

1. O 491258 Figure 7 4 Control Board TEST TEST POINTS CALLOUTS VOLTAGE CONDITIONS REMARKS 1 TP N to TP E 2to 13 40 0 21 0 1800 RPM Idle No Load 2 TP M to TP E 14 to 13 40 0 210 1800 RPM Idle No Load 3 TP C to TP E 3to 13 20 0 1800 or Idle No Load 4 TP D to TP E 12to 13 20 0 1800 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 1110 13 15 0 1800 or Idle No Load 7 TP F to TP E 5 to 13 4 3 1800 Idle No Load TP G to TP E 7 to 13 4 3 1800 Idle No Load TP H to TP E 91013 4 3 1800 or Idle No Load 8 TP J to TP E 6to 13 18 3 1800 or Idle No Load TP K to TP E 81013 18 3 1800 Idle TP L to 10 to 13 18 3 1800 or Idle No Load Table 7 2 December 1 1997 Revised 7 5 430429 231 TROUBLESHOOTING This page intentionally left blank 7 6 December 1 1997 Revised 430429 231 PARTS LIST PARTS LIST Eguipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inguiries This information is usuall
2. CONTROL MODEL SPECIFICATION CONNECTION BOX ENGINE NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM 6298C 1 494148A 494699 494148A Mega Arc 4030D 6298D 1 494148A 494699 494148A December 1 1997 Revised 12 BOARD CONTROL Se M BREAK OFF BRASS JUMPER FINISH CODE PER 800001 NONE DIAGRAM CONNECTION PERKINS MEGA ARC WELDERS SHEET 1 OF 4 4941484 PART LOCATION NUMBER 90 oF NUMBER IL 7 ap WRE COLOR SANGE PO DARE TEREAKI 1 33 REM PAL 6 21 01 CEE e jit eem 1100009 i34 3000 swu pus MAAR x xm 8nd 10131 151 0182 390198 1 IU 5 925 JO ONIMIJ NONY 3SVHd AB DIGWONd SI TOMLNOD INJYYNI YOLDVIY ALNIGVIS IHA OIZNIBVIS 1 PU 0149 30238 104100 HIOTIM A8 B3MOd DO 01 03144934 St H01YH3N39 INIGIIM JHI 30 104100 JHU S 31 V14323M ONY ASIE JHI 01 Y3IMOd 53044015 MOIYM3N3O 501313 303 20 01 YOLYYINID JU 40 INdINO 30 Ov BHI 5313003 182 341935 390198 30010 3110 3 7135 51 YALIOX3 YOLWYINID JHL NOUVY3dO JO AYOJHL OL dIHIS SUNIY HIS 2 I
3. 4 1 Portable Installation 4 1 Initial Preparation For Use 4 2 Welding Leads gt Gorbat anh aita ims 4 3 OPERATION 5 Prestarting Instructions i ue des o ROB NOR 5 1 Break inProcedures mt a a duos bd 5 2 Prewelding Instructions 5 2 Weldirig 245 e teed an A LA 5 3 Stopping The Engine 5 3 Storage da an deg ate aa la 5 3 Adverse Weather Precautions 5 3 MAINTENANCE 6 Engine And Related Components 6 1 Inspection And Cleaning 6 1 LUDIAGCAION Sa at get Ue o RN ake a qxe du 6 1 Exciter Auxiliary Brushes 6 1 Failure To Build 6 2 December 1 1997 Revised Page 1 430429 231 Table of Contents TROUBLESHOOTING PARTS LIST Equipment Identification How Use This Parts List MATERIAL SAFETY DATA SHEET DIAGRAMS Page 2 December 1 1997 Revised 430429 231 INTRODUCTION INTRODUCTION How To Use This Manual This Owner s Manual usually applies to just
4. 40300 30 Amp Constant Current Diesel Engine Driven Welding Generator For the Following Specs 6298C 1 e 6298D 1 IHERMAL THERMADYNE Company OWNERS MANUAL Number 430429 231 Revised December 1 1997 THERMAL ARC INC TROY OHIO 45373 1085 U S A 430429 231 Table of Contents CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of 15 constituents are known to the State of Califomia to cause cancer birth defects and other reproductive harm INTRODUCTION 1 How To Use This 1 1 Equipment Identification 1 1 Receipt Of Equipment 1 1 SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EGUIPMENT 3 Generator a uu A Bona due DA Yu eet 3 1 ENGIN tes a A Oa s e us ui d om s 3 1 Identification coa 3 1 4 ei m RD 3 1 Supplementary Materials 3 2 Engine Controls and Instruments 3 2 Generator Controls 24 2 4 ord DE REUS Rus A qo x 3 3 INSTALLATION 4 General Engine Driven Welder Installation 4 1 LOCATION aee doe a gi aa e ue Ed usd ua 4 1 SUID Ge Ok diva 4 1 Indoor Installation
5. SAS Current Door Control Or ep corte Fuel Gauge O 5 Contactor 2 9 gontrol lt _ gt gt O O o Remote 1 ontro ibi Throttle laniti Hour Switch Bashbation Alternator Water Meter i 19 Te oil Ha n Gauge Figure 3 1 Control Panel Supplementary Materials Throttle This control shuts the diesel fuel A copy of the Perkins Handbook for Diesel En supply off for normal shutdown of the engine Pull gines is included with each welding generator unit the control handle OUTall the way for engine to run Additional copies may be obtained from the manu at rated RPM 1800 Push the handle against facturer the panel to shut engine down Turn control handle counterclockwise to loosen and clockwise to lock it Engine Controls and Instruments in position Ignition Switch The diesel engine starting motor is actuated by this switch located in the lower Thermostart Pushbutton Place the starter left hand corner of the control panel Do NOT crank switch in RUN position and hold the pushbutton N the engine for more than 30 seconds at a time as for 15 to 20 seconds prior to placing the starter this may cause the starting motor to overheat Allow switch START position Continue to hold it N until motor to cool before attempting to start the engine engine fires again Place switch in START position to start and return to RUN position after the engine has started
6. When engine is shut down place switch in OFF CAUTION Do hold the pushbutton position IN for any longer period of time than the 20 seconds above If engine does not NOTE Switch must be in OFF position to start first time place starter switch in avoid lighting the Alternator and Oil Pres OFF position then repeat above proce sure light dure 3 2 December 1 1997 Revised 430429 231 DESCRIPTION OF EQUIPMENT Oil Pressure Light Glows red when oil pres sure 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 coolanttempera 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 welding 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 lengt
7. 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 Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT Do not remove radiator cap when engine is hot Allow engine to COOLANT can burn face eyes and cool skin Wear gloves and put a rag over cap area when removing cap The coolant in the radiator can be very hot and under Allow pressure to escape before completely removing cap pressure 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 8 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 Biological Effects of Power Frequency Electric 8 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 e
8. 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 It is important to note that in the LOW range 15 to 200 amperes at mini mum setting of the Current Control the open circuit voltage will drop to a lower value and vary slightly with the current con trol 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 NOT turn the unit ON Disconnect the 7 2 December 1 1997 Revised 430429 231 TROUBLESHOOTING leads from the generator to the rectifier assembly and check with a VOM for shorted SCRs and di odes An open gate or an open SCR cannot be checked with a VOM If an SCR is 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 TwoNot Not Firing Firing Firing Firing Max OCV 75 V DC 50 V DC 25 V DC 0 V DC 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
9. plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 2 3 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC Instruction 830002 DES PIECES EN MOUVEMENT PEU VENT CAUSER DES BLESSURES Des pieces 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 contiennent 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 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les mains
10. 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 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 N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publica tion P 1 de la CGA identifi e dans la liste de documents ci dessous 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 Si c est possible laissez le moteur refroidir avant de faire le
11. Keep system clean and free from water which may collect in a low 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 c Cooling System Prior to cold weather drain ad flush the cooling system to remove accu mulations of rust and sediment Mix and add anti freeze 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 of oil See Engine Oil Recommendations chart in the Maintenance and Operator s Manual for recommended viscosity oil for various atmospheric temperatures In cold weather drain oil more fre quently Water condenses and collects quickly mixes with the oil and increases deposits to form a sludge Check oil frequently for th
12. manual APPLICATION NUMBER A B December 1 1997 Revised 8 1 430429 231 PARTS LIST Item No Figure 8 1 Control Panel Parts List for Figure 8 1 Part Description Aty Application Number per Code Assy 494119 4 Panel Control Assembly 1 A 494119 7 Panel Control Assembly 1 494096 Panel Control 1 A 494096 1 Panel Control 1 B 404089 Receptacle Duplex 3 Wire 230 V 1 AII 403091 4 Plug Hole Plastic 1 AII 403091 12 Plug Hole Plastic 1 8 2 December 1 1997 Revised 430429 231 PARTS LIST Parts List for Figure 8 1 Item Part Description Aty Application No Number per Code Assy 5 79C 1149 1 Meter Engine Hour 1 All 6 494150 1 Gauge Water Temp 1 All 7 406004 1 Light Snap Mt Red All 8 Deleted 9 403091 2 Plug Hole Plastic 1 All 10 30GH 1119 Switch Pushbutton 1 11 494134 1 Gauge Fuel 1 AII 12 404856 Switch Toggle DPDT MOM ON 1 13 405982 1 Cover Hole Meter 2 AII 14 402670 Receptacle Duplex 3 Wire 115 V 1 All 15 409527 3 Circuit Breaker Thermal 3 All 492010 2 Box Control Assembly 1 A 492010 8 Box Control Assembly 1 B 16 492036 Box Control 1 A 492036 1 Box Control 1 B 17 406003 2 Strip Terminal Q C 12 Station 1 All 18 406003 1 Strip Terminal Q C 6 Station 1 All 19 404915 1 Spacer Board 6 All 20 491238 Board P C Control Assembly 1 All 21 W 11166 9 Fuse
13. 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 d gelez pas les tuyaux avec un source de courant Otez l 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 des 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 LES ETINCELLES 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 Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles 4 un support ou a un cadre fixe pour les emp cher de tomber ou d tre renvers es 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
14. 1 Amp Fast Blow 6 22 405129 1 1 AII 23 367579 Insulator Fuse Block 1 All 405157 Label Fuse 1 AII 491454 Door Control Box Assembly 1 A 491454 1 Door Control Box Assembly 1 B 24 491446 Door Assembly 1 A 491446 1 Door Assembly 1 B 25 406040 Boot Toggle Switch 3 AII 26 405365 1 Switch Toggle SPST 1 All 27 367703 1 Resistor 1 2 Watt Assembly 1 All 28 406926 1 Potentiometer 2 Watt 5 2 All 29 492576 Board Pot 1 All 30 402663 Nut Pot Lock 2 All 31 406806 1 Knob Control 1 A 406806 3 Knob Control 1 B 32 491773 1 Knob Control 1 A 491773 3 Knob Control 1 B Not Illustrated December 1 1997 Revised 8 3 430429 231 PARTS LIST This page intentionally left blank 8 4 December 1 1997 Revised 430429 231 PARTS LIST Parts List for Figure 8 1 Item Part Description No Number 33 8BW 106A Spacer 34 402682 Switch Toggle 35 400758 Receptacle 6 Pin Amphenol 36 404875 Cap 8 Chain Assembly 37 494097 Panel Rear Lower 494097 1 Panel Rear Lower 38 DW 4333 Rod Throttle Not Illustrated Aty Application per Code Assy All All All All lt gt py December 1 1997 Revised 8 5 430429 231 PARTS LIST Figure 8 2 Frame Group 8 6 December 1 1997 Revised 430429 231 PARTS LIST Item No Part Number 491461 2 491461 6 5J 260 0 5J
15. 231 OPERATION OPERATION WARNING 40300 mounted atrailer 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 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 Make sure that no loose bars tools parts etc are in or on any part of the engine as they could December 1 1997 Revised 5 1 430429
16. 231 OPERATION cause serious damage to the engine generator or 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 welding 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 which will aid in preventing wet stacking 1 Open the fuel shut off valve at fuel tank 2 Start the engine see instructions un
17. 260 3 356773 38 491897 491464 491463 402530 402788 402531 356773 42 491784 491658 1 No Number 492300 2 491758 1 491758 3 491813 491813 1 351683 491479 491479 1 31 Parts List for Figure 8 2 Description Generator Assembly Generator Assembly Cap Bearing Cap Bearing Housing Exciter Assembly Armature Brushholder Assembly Bracket Brushholder Guide Brushholder Brush Cap Brushholder Housing Gen Assembly Ring Adapter Fan amp Coupling Assembly Flywheel Supplied W Engine Housing Flywheel Cover Hole Flywheel Housing Cover Hole Flywheel Housing Cover Gen Housing Cover Gen Housing Grommet Lead Hole Cover Exc Housing Cover Exc Housing Key Coupling Qty Application per Code Assy A dd NN ND HAH AH AH ASH AS A B A B All All All All All All All All All All All All December 1 1997 Revised 8 7 430429 231 PARTS LIST Figure 8 3 Generator Group December 1 1997 Revised 8 8 430429 231 PARTS LIST Parts List for Figure 8 3 Item Part Description Aty Application No Number per Code Assy 1 492364 1 Top Canopy 1 A 492364 3 Top Canopy 1 B 2 409158 Label Danger 1 AII 3 405089 Label Fuel 1 All 4 406000 Label Warning Fuel 1 All 5 494445 Label Precautionary 1 All 6 494130 Shield Safety 1 All 7 494133 Cap Fuel Tan
18. Antimony CAS 7440360 0 50 mg m 0 50 mg m Appearance and Odor clear odorless colorless Solubility in Water completely Boiling Point approximately 235 F Specific Gravity 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 hydrogen gas Extinguishing Media Class ABC extinguisher CO and or Halon LEL 4 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 ignition Stability Stable Condition to Avoid Cases decompose at 160 410 322 770 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 Hazardous Polymerization will not occur Conditions to Avoid not applicable Page 1 of 2 MSDS Battery Wet Filled with Acid 8 UN2794 PGIII 2 of 2 Route s of Entry Inhalation skin contact and ingestion Health Hazards Acute and Chronic Short
19. Arc Order Department 2200 Corporate Drive Troy Ohio 45373 1085 Include all equip ment 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 e 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 e Avoid sudden jerks drops or swinging e 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 of this manual may be pur chased by contacting Thermal Arc at the address given above Include the Owner s Manual number and equipment identification numbers December 1 1997 Revised 1 1 430429 231 INTRODUCTION This page intentionally left blank 1 2 December 1 1997 Revised ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND W
20. Volts Voltage max 75 Volts Duty Cycle 100 Current Range Low Range 1510 200 A High Range 30 to 400 A Operating Speed See Engine Data Engine Make and model Detroit Diesel Perkins 3 152 TYPE tee eae E Industrial diesel Displacement 152 cu in 2 50 liters Brake horsepower 38 BHP 9 1800 RPM Oil sump 7 1 2 quarts 7 liters Cooling system capacity 9 1 2 guarts 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 E 40 inches 1016 Height over eye in top E 45 inches 1143 mm Weight shipping EUREN approx 1600 pounds 726 kg December 1 1997 Revised 3 1 430429 231 DESCRIPTION EQUIPMENT Range Selector Current Arc Force 15 Amp Switch Control Ampere Control Circuit Breakers Voltmeter Optional Ammeter Optional 0 115 Volt o Receptacle 230 Volt Receptacle Control Box
21. cleaner daily Replace oil filter cartridge as needed Change element in the air cleaner as required Crankcase The crankcase oil level will bear close attention Dusty conditions tend to load crankcase oil with dirt Watch for dirty and gritty oil conditions and change oil more frequently as re quired 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 gen erator 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 gen erator and exciter should be inspected regularly to make certain that they are free in the holders Lift the 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 and commuta tor care d Field Coils The fields should be dried as thoroughly as possible If they have become damp proceed with recomm
22. 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 unitis to be stored outdoors itis 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 supplied 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 performance or total functional failure is to be avoided Consult Engine Workshop Manual and recommendations below a Fuel System
23. curit 1 Portez une casque de soudeur avec filtre oculaire de nuance Portez un casque antibruit ou des bouchons d oreille approuv s appropri e consultez la norme ANSI 749 indiqu e lorsque le niveau de bruit est lev 8 V 96 2 1 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE Operation de Coupage ou soudage Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage l arc 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 l arc avec lectrode de carbone CAW Soudage l arc Plasma PAW Gougeage Air Arc avec lectrode de carbone mince pais Coupage l arc Plasma PAC mince moyen pais selon AWS 8 2 73 Dimension d lectrode ou Epaisseur de m tal ou Intensit de courant toutes conditions 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 3 12 mm plus de 1 2 po 12 mm moins de 5 32 po 4 mm de 5 32 1 4 po 4 6 4 mm plus de 1 4 po 6 4 mm toutes conditions toutes conditions toutes co
24. 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 crankcase If itis necessary to add oil fill to dipstick mark with correct seasonal grade of quality deter gent oil See engine operator s manual for recom mended 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 Re ceptacle 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 POSITIVE 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 dow
25. 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 ARC RAYS can burn eyes and skin Wear a welding helmet fitted with a proper shade of filter see NOISE can damage hearing ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended Arc rays from the welding process produce intense Use protective screens or barriers to protect others from flash heat and strong ultraviolet rays that can burn eyes and glare warn others not to watch the arc de pith Noise from some processes cam damage Wear protective clothing made from durable flame resistant 9 material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high Eye protection filter shade selector for welding Electrode Size i Electrode Size Welding or Cutting Metal Thickness Welding or Cutting Metal Thickness Operation or Welding Current Operation or Welding Current Torch soldering Gas metal arc welding MIG Torch brazing Non ferrous base metal AII Oxygen cutting Ferrous base metal AII Light Under 1 in 25 mm Gas tungsten arc welding TIG Medium 1 to 6 25 150 mm Atomic hydrogen welding All Heavy Over 6 in 150 mm Carbon arc welding All Gas welding Plasma arc welding All Light Under 1 8 in 3 mm Carbon arc air gouging Medi
26. ou les cheveux de pi ces en mou vement elles peuvent aussi accrocher des v tements amples et des outils 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 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule Utilisez la polarit correcte et de l accumulateur 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 l ter Laissez la pression s chapper avant d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI Z49 1 American Welding 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 Protect
27. 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 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 EN E A fil ce dernier le rouleau ou la bobine de fil le N utilisez pas de c bles lectriques us s endommag s mal logement des galets d entrainement et toutes les piss s ou de section trop petite pi ces m talliques en contact avec le fil de soudage N enroulez pas de c bles lectriques autour de votre corps sont sous tension Un quipement inad quatement N utilisez qu une bonne prise de masse pour la mise la terre install ou inad quatement mis la terre est dangereux de la piece souder Ne touchez pas des pi ces sous tension Ne touchez pas l lectrode lorsqu en contact avec le circuit de Portez des gants et des v tements isolants secs et non trou s soudage terre Isolez vous de la pi ce souder et de la mise la terre au moyen N utilisez que des quipements en bon tat R parez ou rem de tapis isolants ou autres placez aussit t les pi ces endommag es D co
28. 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 drops to a lower value it will indicate that this particular SCR is working properly Reconnect this lead and proceed to do the same with the remaining two leads until you discover which disconnection does not cause the OCV to drop to a lower level This will be the SCR which should be changed Printed Circuit Board Testing The next step is to 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 8 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 2 Apply a thin coat of Alcoa 2 compound to cleaned surface Alcoa 2 is available from Thermal Arc part number 903870 8 Positively locate the SCR in place in t
29. 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 in 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 breathing apparatus Reference DOT UN2796 Waste Disposa
30. which the brush contacts the slip rings Figure 6 1 Exciter Auxiliary Brushes December 1 1997 Revised 6 1 430429 231 MAINTENANCE 5 To fit new brushes to the slip rings lay a strip of No 00 sandpaper smooth side down on slip ring surface and draw the sandpaper in the direction of rotation of the slip rings lifting the brush on the return stroke Continue until the brushes have the same curvature as the slip rings Blow all carbon dust out of the machine using not over 25 psi 172 kPa air pressure Failure To Build Up Voltage Refer to Connection Diagram in Diagrams chapter included in this manual One common problem with engine driven gener ators is failure to build up voltage from loss of residual magnetism in the fields Check all wiring from the exciter stator T1 T2 to rectifier CR1 and to slip rings SR Also check Parallel Field Resistance E s CR1 diode bridge for a shorted diode which would not allow unit to build up If this check does not solve problem check the revolving fields for continuity as explained below See Figure 6 2 To check for revolving field coil problems it is necessary to understand that there are two field circuits permanently paralleled at the slip ring con nections A good armature will snow 9 ohms resis tance measured at the slip rings with brushes lifted from rings Ifthe resistance measured at the rings is 12 ohms thenthe exciter revolving fie
31. 6 22 01 2269 2 e ADT i ins 5 16 62 11 1100008 13d 3009 HSINIJ 930933 a NOUNARUSO us PAE EEE 5 52227225 MESES he cates PARS os Bnd 23 0 01043105 E 7775 y 134 5 5 xd 8 44 MIONIS dW31 YILINYNOH HOLIMS 3unss3ud 91043105 1891 1102 INIYYND NV HOLIMS QION310S NI HOLAS 0333 8 asna y OLY oy vue 03395 339435 HIONIS JYNSSIYd 3onvo 1383 010437105 HIINVIS s S aauvs DOA TI 3555358 10 Yli 5 V YOIVNY3LTW 9 CE rore HOUMS JOITVISNI 30010 MOD 1YVISONY3HL YOLVNY3 Q3TIVISNI 1 1515 M3H13 N3HM LIINNOISIG 19 15 Xnv iva VST 12657 OHO ADAL oj paeganp 20 pagos tu NO kpatoid PURAN pus hi t Mi 4431 YO JAOBV yOu LT 30100 Y Guim 6 22 L CHER GEEK IN SUV 101409 M NI HIM HN NOIL23NNOO 10
32. 94459 8 Spacer Insulator 2 All 34 494459 2 Spacer Insulator 2 All 492533 3 Panel Terminal Assembly 1 A 492533 6 Panel Terminal Assembly 1 B 35 492532 1 Panel Output Weld 1 A 492532 2 Panel Output Weld 1 B 36 5CW 974 Bar Bus 2 All 37 No Number Nut 1 2 13 HWH ST 2 All 38 5CW 975 Bushing Insulator 2 All 39 5CW 976A Washer Insulating 4 All 40 No Number Washer 1 2 FL ST 2 All 41 No Number Washer 1 2 LK ST 5 All 42 351505 Screw 1 2 13 x 1 3 4 2 All 43 368705 7 Capacitor Assembly 2 All 44 No Number Screw 6 30 x 3 16 Hd MH 2 All 45 No Number Washer 1 2 FL ST 3 All 46 367687 Shunt 1 All E W 9234 338 Output Term to Rect 1 W 9234 339 Cable Output Term to Reactor 1 All 47 491763 1 Door Side 2 A 491763 3 Door Side 2 B 48 490174 Plate Hinge 12 All 49 490040 Hinge Door 6 All 50 490234 Latch Door 4 All 51 493457 Spacer Latch 4 All 52 492244 Handle Door Latch 4 All 53 406155 Muffler 1 All 54 406080 Engine Diesel 1 All 55 W 10750 2 Nipple Pipe 1 All 56 W 10910 0 Tee Pipe 1 8 1 All 57 402130 Switch Oil Pressure 1 All 58 409159 Switch Oil Pressure 1 All 494824 Spacer Fan 1 AII Not Illustrated December 1 1997 Revised 8 11 430429 231 PARTS LIST This page intentionally left blank 8 12 December 1 1997 Revised 430429 231 PARTS LIST Parts List for Figure 8 3 Item Part Description Aty Applic
33. ARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOTLOSE THESE INSTRUCTIONS READ OPERATING INSTRUC MANUAL BEFORE INSTALLING OPERATING SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other eguipment 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 eguipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to eguipment connected to power lines other practices apply to engine driven eguipment Safe practices are outlined in the American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides 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 Turn off all 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
34. Barbed Valve 1 4 Turn Shut Off Line Return Hose Rubber Adapter Tube to Pipe Elbow Street 45 Speed Control Section Arm Fuel Shut Off Spring Pivot Throttle Bushing Throttle Clamp Throttle Rod Support Throttle Rod Support Throttle Rod Bracket Spring Bracket Spring Spring Bracket Spring Bracket Spring Aty Application per Code Assy gt Ad All All All All All All All All All All December 1 1997 Revised 8 17 430429 231 PARTS LIST This page intentionally left blank 8 18 December 1 1997 Revised EAST PENN manufacturing co ine Material Safety Data Sheet BATTERY ELECTRIC STORAGE DRY Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc 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 contine Hazardous Components Specific Chemical Identity Other Limits Common 5 OSHA PEL ACGIH TLV Lead and Lead Components 0 050 mg n 0 15 mg m Appearance and Odor N A Solubility in Water N A Boiling Point N A Specific Gravity H 0 1 N A Evaporation Rate Butyl Acetate 1 Vapor Density AIR 1 N A Melting Point N A Vapor Pressure mm Hg Flash Point Method Used N A Flammable Limits N A LE
35. 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 of the 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 Mega Arc 4535D machine to be normal and similar to many of the conventionally controlled engine driven stick electrode welding machines However turning down the Arc Force Control to the 2 to 4 or SMOOTH range gives a softe
36. L Extinguishing Media Dry chemical carbon dioxide water spray or foam 5 1 1 Fire Fighti 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 Electric Storage Dry page 2 of 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 Section VI Health Hazards Lead Waste Di
37. N3MMO2 1081 HILMS TOHLNOI HOLIVINOI 7101 HOLS HOLWS 3ONYM 3313NOUN310d 39403 IOMLNOD INIYUNI 30151534 MOT 140 INNHS 3138 1NnHS YOVEOTIS 644 05 01553 0 01384 SWHO OS SMOLSIS3H YIBONNS 19 190 MALUS YOLVYINID Nid 9 ION3HANY 319143338 13uno 131100 43404 Xv ASI 30123NN03 ONVOR NIYII 53574 QWvOB8 LIINID M3UU 238 1ndinO AINIM 3908 4341239 01313 dWYSL SYIAVIVO 17232 5 0112 4 2 NOISSIVAANS 3SION 90 00 GIN 2 0 74 334930 439 X 7Z 3 nssv SIHUVUIAMIL 83H10 LV 5153 3 518 0 GOT 3 54 OUVF 64 5 53 0134 TITIVHVd 3 510 DUTY 91 01 YNUY34 1OMINOO 310838 1NOHLM X000 TOHINOD 30 SNOU23NNOO tr ZUM 30 F 143 MO s O LT 3009 384 g JUM NOUONNO2 i E UE 1 Nous SY 8 100008 134 3009 CE c pw Ege AI Y Vois 7 i x cot Bk Exc 7 3onds da 3TIVISNI LAAS pe ES i de iE HEC TN ulo te 1 en
38. ND 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 under high 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 mechani cal 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 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 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 contai
39. NES can be hazardous 1 2 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes 2 2 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 Donotadd 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 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 SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin
40. NINOO 5 F Fa Juu SOYYONYIS 0317000939 Ot na 2245 LOIG Add MOTS SIONVUMIOS lo SUMATRA SIMON JW 5 055140 il m ON RRA 931312395 ISIMY3HIO SSTINN ets SDN pH vn uva 3NON 100008 333 3000 HSINIJ NOUNEMISO 040934 JINVHI 8 HIAL 6 6 451 VIS 21 40018 IVNINYIL zal VIS 9 0018 WNINUIL 181 1041 H LMS cs 1041 HOLIMS 25 1545 HOLIMS 1 AS MZ 8313WOllN310d 01Y 6Y 2 1 HOLSIS3N eu Nid 9 ION3HANV 310V1d3038 gr VIS L 310V1d323M ONISNOH VIS Zt 310V1d303M ONISNOH a VIS 6 319 19393 ONISNOH tr 1572 29 dWv 3SN4 93 63 QN3931 ae ee pe p Vol 2 duvog Id 108109 lt Nis y 181 3135 281 zu D KU D KD lO O LO 20 23 0 ss NNINNNN oo Anan STATEMENT OF WARRANTY LIMITED WARRANTY Thermal Arc Inc 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 specificat
41. QUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les regles 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 Z49 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 conna tre 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 ENTRETIEN ET D ESSAI L ELECTROCUTION PEUT ETRE 6 Arr tez tout quipement apr s usage Coupez l alimentation de MORTELLE l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer
42. RMAL ARC ALTHOUGH MOST ARE WARRANTED 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 all 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
43. SA Standard W117 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 287 1 from American National Standards Institute 1430 Broadway New York NY 10018 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy 02269 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 8 1996 2 3 WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 This page intentionally left blank 2 4 May 8 1996 PRECAUTIONS SECURITE SOUDAGE L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET E
44. URCHASER S RIGHTS UNDER THIS WARRANTY ARE 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 THE
45. ake 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 of the welding machine must be placed at the tongue end of the portable mounting for December 1 1997 Revised 4 1 430429 231 INSTALLATION proper balance Ifleads etc are to be stored onthe unit they must be forward of the axle to maintain proper balance of loading on the tongue end ofthe 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 sideways 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 aclosed position during operation ofthe unit if it is resting 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 worki
46. armature 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 December 1 1997 Revised 7 1 430429 231 TROUBLESHOOTING Output voltage too low Engine running underspeed Check engine RPM One or more revolving field coils shorted Replace defective coils Engine See Detroit Perkins Handbook For Diesel Engines 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 not overlook the 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 The following voltages should be read at 1800 RPM eng
47. ation No Number per Code Assy 59 491673 1 Support Engine 2 A 491673 2 Support Engine 2 B 60 491672 Spacer Mtg Engine 2 A 491672 1 Spacer Mtg Engine 2 B 61 406178 Label Oil Filter 1 62 494128 Panel Side Right 1 A 494128 1 Panel Side Right 1 B 63 409554 1 Rectifier Assembly 1 6 202258 5 Suppressor W Lugs 1 All 64 367634A 5 Suppressor Surge Assembly 1 All 65 492049 Bracket Mtg Bus Bar 1 All 66 492047 Bar Bus 1 All 403618 7 Belt Fan 1 All 67 406149 Fan Engine 1 All 68 Deleted 69 494181 Alternator Delco 1 All W 9360 229 Cable Bonding 1 All 70 494149 2 Sender Water Temp 1 All 71 No Number Filter Fuel Supplied W Engine 1 All 72 491721 1 Bracket Mtg Fuel Filter 1 A 491721 2 Bracket Mtg Fuel Filter 1 B 73 492362 1 Panel Front 1 A 492362 3 Panel Front 1 B 74 491689 1 Plate Front End 1 A 491689 23 Plate Front End 1 B 75 491690 1 Support Radiator 2 A 491690 2 Support Radiator 2 B 76 406981 1 Radiator 1 All 77 406989 Cap Radiator 1 All 78 W 10869 12 Clamp Hose 4 All 79 406977 Hose Radiator Top 1 All 80 493252 1 Shroud Fan 1 A 493252 2 Shroud Fan 1 B 81 405977 2 Hose Radiator Bottom 1 All 82 494741 Guard Fan 1 All 83 406001 Label Caution 2 All 84 494725 Brace Guard 1 All 85 5CW 1932 0 Block Drain 1 All Not Illustrated December 1 1997 Revised 8 13 430429 231 PARTS LIST This page intentionally left blank 8 14 December 1 1997 R
48. der 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 8 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 operating 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 prob lem in order to burn out the unburned hydrocarbons that accumulate in the ex haust stack Prewelding Instructions To adjust weld current and arc characteristics while welding the High Low Range Switch Current Control and Arc Force
49. duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage 2 2 8 V 96 PRECAUTIONS DE SECURITE SOUDAGE L ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN CENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le metal 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 des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 metres autour l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la 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 Connectez le cable de soudage le plus pr
50. ended procedure in Mainte nance chapter e Battery Terminals Thoroughly clean the battery terminals and connections Coat terminals and connections with petroleum jelly to retard cor rosion 5 4 December 1 1997 Revised 430429 231 MAINTENANCE 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 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 electric light bulbs to effectively dry out the windings If dampness is excessive apply external heat under a canvas cover well vented Heating shou
51. evised 430429 231 PARTS LIST Parts List for Figure 8 3 Item Part Description Aty Application No Number per Code Assy 86 492133 4 Cable Batt Pos 1 87 492132 3 Cable Batt Neg 1 88 491962 1 Clamp Battery 1 A 491962 2 Clamp Battery 1 B 89 494295 Rods Battery 2 90 491122 Angle Front Panel 2 A 491122 1 Angle Mtg Front Panel 2 B 91 491680 1 Frame Mounting 1 A 491680 1 Frame Mounting 1 B 92 491683 1 Bar Mtg Gen 1 A 491683 2 Bar Gen 1 B 93 406254 3 Mount Shock 4 94 491799 Washer Shock 8 A 491799 1 Washer Shock 8 B 95 494129 Panel Side Left 1 A 494129 1 Panel Side Left 1 B 96 402086 2 Battery 1 493797 2 Protector Batt Term 1 AII 357013 Clamp Throttle Rod 1 All 97 494730 Guard Alternator 1 All Not Illustrated December 1 1997 Revised 8 15 430429 231 PARTS LIST Figure 8 4 Fuel Lines and Speed Control 8 16 December 1 1997 Revised 430429 231 PARTS LIST Item No o gt 10 11 12 13 14 15 Parts List for Figure 8 4 Part Number 492288 1 490036 W 10869 14 355325 10 355325 16 405091 1 402265 492075 491889 4 402927 1 12CW 2125 490186 400562 32 490028 16DW 34 494541 490010 490010 1 492360 492360 1 W 799F 110 490073 490073 1 Not Illustrated Description Line Fuel 8 Return Line Fuel Clamp Hose Hose Rubber Hose Rubber Elbow Male
52. h is shortened Turning 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 fur nish 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 December 1 1997 Revised 3 3 430429 231 DESCRIPTION EQUIPMENT VOLT AMP CURVES MODEL MA 4030D TYPICAL WELDING VOLTS DC ARC FORCE SETTINGS 0 100 200 300 400 500 600 WELDING AMPS DC Volt Ampere Curve 3 4 December 1 1997 Revised 430429 231 INSTALLATION INSTALLATION General Engine Driven Welder Installation The frame of an engine driven welder 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 al
53. he heat sink A small spring pin inthe 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 Place the Force Indicator Gauge 903878 firmly against the 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 deflection or force Correct mounting force is indi cated as shown below 8 Spring deflection over 2 1 4 inches of spring is 037 002 for all clamps 9 clamps to be set at 4 mark This corre sponds to the VE3000 VE2500 section on the gauge label December 1 1997 Revised 7 3 430429 231 TROUBLESHOOTING Force Gage shown in position 903878 Clamp 405140 2 Heat Sink A Sink Figure 7 1 To Calibrate Force Gauge Examples Top edges lined up 488 Less than rated Correct rated Excessive force force Tighten force Loosen both nuts alternately nuts and start 1 4 turn ata over Never ad time until points just force by coincide backing off the nuts Friction will produce a false reading Always start from Step 1 Figure 7 2 If the gauge is suspected of being out of calibration due to wear or damage check it on a flat surface as show
54. ine speed 1 Welding Generator phase to phase on all three phases 60 V AC 10 2 Phase to Neutral of Welding Generator 35 V AC 10 3 Check for blown fuses F3 F8 Refer to Diagram 492107 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 or low 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 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 control on the front of the 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 If the 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 approxi mately 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
55. ion Association Batterymarch Park Quincy MA 02269 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 2 4 8 V 96 430429 231 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT Generator The diesel engine driven arc welding machine is a self 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 welding generator and auxiliary exciter gen erator revolving fields are mounted on a single heavy duty shaft supported by a ball bearing at the exciter end of the shaft and by the engine coupling at the other end The welding generator is 300 ampere 100 duty cycle or 400 ampere 60 duty cycle 3 phase wye connected rectified to DC power by the output rectifier and stabilized by the stability reac t
56. ions instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal 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 conseguential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser 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 P
57. is condition Water December 1 1997 Revised 5 3 430429 231 OPERATION in crankcase or oil lines may freeze and cause serious damage to the oil pump or shut off the oil supply e Battery Battery efficiency decreases sharply with lower temperatures Maintain the spe cific 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 freguent check of the coolant level in the radiator b Battery The specific gravity and proper level the battery electrolyte should be maintained Observe recommendations in the Maintenance and Operator s Engine Manual for proper care of the battery Operation In Extremely Dusty Conditions If 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 temporary erect a protection shield a Fuel System Drain the fuel water trap sediment bowl frequently and keep all fuel contain ers covered and protected against dust entry b Oil Filter and Air Cleaner These both need more frequent attention under dusty conditions Check air
58. k 1 All 8 DDW 495 8 Cap Rain 1 All 9 407366 Label 1 All 10 359699 Brace Canopy 2 A 359699 1 Brace Canopy 2 B 11 406187 Bracket Mtg Air Cleaner 2 All 12 406927 Cleaner Air 1 All 13 W 10869 3 Clamp Hose 2 All 14 406945 Hose Air Cleaner 1 All 15 491414 Reactor Stability Assembly 1 All 16 494127 Tank Fuel 1 All 17 494135 1 Sender Fuel Gauge 1 All 18 494139 Support Fuel Tank 1 A 18 494139 1 Support Fuel Tank 1 B 19 492191 Panel Heat Shield 1 A 492191 1 Panel Heat Shield 1 B 20 491820 Support Heat Shield 1 A 491820 1 Support Heat Shield 1 B 21 492195 Cover Heat Shield 1 All 22 406358 2 Resistor Preload 1 All 23 494456 Yoke Lifting Assembly 1 A 494456 1 Yoke Lifting Assembly 1 B 24 402037 11 Grommet Lifting Yoke 2 All 492368 1 Rectifier Output 1 All 25 482367 1 Plate Rect Output Right 1 All 26 492366 Plate Rect Output Left 1 All 27 W 10931 3 Rectifier Silicon Controlled 4 AII 28 405140 1 Clamp Mounting 3 29 492413 Heat Sink SCR 3 Not Illustrated December 1 1997 Revised 8 9 430429 231 PARTS LIST This page intentionally left blank 8 10 December 1 1997 Revised 430429 231 PARTS LIST Parts List for Figure 8 3 Item Part Description Qty Application No Number per Code Assy 30 405826 Rectifier Silicon Controlled 3 All 16DA 954 12 Spring 3 All 31 494459 1 Spacer Insulating 2 All 32 410223 6 Tubing Fiber 2 All 33 4
59. ka 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 Hazardous Components Specific Chemical Identity Other Limits Common Name s Recommended Percent 30 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 Unusual Fire and Explosion Hazards Stability Stable Condition to Avoid Contact with metal may release explosive hydrogen gas Incompatibility 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 Page 1 of 2 MSDS Battery Fluid Acid 8 UN2796 PGII 2 of 2 Route s of Entry Inhalation skin contact and ingestion Carcinoge
60. l Method Lead acid batteries are completely recyclable For information on returning batteries to East Penn for recycling call 610 682 6361 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 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 Material Safety Data Sheet BATTERY FLUID ACID 8 UN2796 PGII Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc De
61. ld 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 Exciter Auxiliary Brushes See Figure 6 1 1 Disconnect leads A from connectors on brush holder caps CAUTION When removing the lead wires do so one at a time and replace each brush accordingly to insure that the lead wires are put back onto the proper brushes 2 Lift brush D from brushholder C for inspec tion If brushes are worn unevenly or are shorter than 7 16 inch 11 mm replace them 3 Inspect slip rings whenever brushes are re moved for servicing brushes or brushholders Note surface condition of rings Surface should appear smooth and clean Scoring or roughness of slip rings may be caused by grit or abrasive substance in brushes or by oil on the rings Moderately rough slip rings can be smoothed by holding grade 00 flint paper against their surface while the rings are re volving slowly If the rings are badly scored the unit must be sent to an overhaul facility for repair After cleaning slip rings blow dirt and grit out of the unit with compressed air Do not use over 25 psi 172 kPa air pressure to blow dirt out 4 Slip new brushes into brushholder guides and place caps on top and screw them into the guides to a bottomed position The spring attached to the brush will determine the pressure at
62. lds 32 ohm coils have an open circuit If the measured resis tance at the slip rings is 32 ohms then the exciter fields 12 ohms have an open circuit A resistance measurement of much less than 9 ohms the slip rings indicates that there is a short circuit some where in the revolving field windings Exciter Slip lip Revolving Welding Generator Ring Ring Fields Revolving Fields Bearing L1 32 Ohms L2 12 Ohms End Figure 6 2 Slip Ring Continuity 6 2 December 1 1997 Revised 430429 231 TROUBLESHOOTING TROUBLESHOOTING The following chart contains information which can be used to diagnose and correct unsatisfactory operation 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 Auxiliary Power Generator Exciter and Welding Generator No output at 115 and 230 V Receptacles or Welding Terminals Unit won t build up voltage Loose connections Check connections completely Open circuit in exciter revolving field Replace armature see detail instructions at end of chart Brush and slip rings dirty Check brushes and clean slip rings Broken wiring Repair Shorted diode in field rectifier bridge Replace bridge No output at welding terminals 115 V and 230 V receptacle output OK Open circuit in welding generator revolving field coils Replace
63. low 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 throughoutthe welder and produce vibration related problems Before choosing an installation location make note of where the service items are located on the welder oil changeffill 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 When 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 electri cally bonded together 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 cutti
64. n below T DI PETE ZZZ True flat surface or straight edge If the calibration edges do not line up calibrate the gauge by filing the bottom contact points Figure 7 3 7 4 December 1 1997 Revised 430429 231 TROUBLESHOOTING
65. n 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 serious damage to or wreckage of engine or gener ator or personal injury to anyone standing nearby 12 Carefully read and follow Operating Instruc tions in your engine operator s manual 4 2 December 1 1997 Revised 430429 231 INSTALLATION 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 TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS Welding ELECTRODE LEAD PLUS WORK LEAD AH 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet mperes 15 2 M 30 5 M 45 7 M 61 0 M 76 2 M 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 42 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 Table 4 1 Suggested Copper Welding Lead Size Guide 40 1016 mm 45 1143 mm 61 1 2 1562 rn a mm Figure 4 1 Dimensions December 1 1997 Revised 4 3 430429 231 INSTALLATION This page intentionally left blank 4 4 December 1 1997 Revised 430429
66. nditions 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 5 Ne travaillez dans un espace confin que s il est bien ventil 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 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 Sila ventilation est inadequate portez un respirateur adduc tion d air approuv 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 sinon portez un respirateur adduction d air Les gaz protec teurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respiration 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 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 si l espace est bien ventil si n cessaire portez un respirateur ad
67. ng 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 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 structed 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 m
68. ng 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 im 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
69. nicity 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 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 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 3 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 positi
70. ning these elements can give off toxic fumes if welded 5 Watch for fire and keep a fire extinguisher nearby 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 rec ommended Wear proper body protection to protect skin Keep cylinders away from any welding or other electrical circuits 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 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 asso ciated equipment and CGA publication P 1 listed in Safety Standards ENGI
71. nnectez la prise d alimentation de l quipement ou arr tez 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 l alimen tension Utilisez plut t une source de courant continu tation afin d viter une mise en marche accidentelle Portez un harnais de s curit si vous travaillez en hauteur Veuillez installer cet quipement et le mettre la terre selon Fermez solidement tous les panneaux et les capots le manuel d utilisation et les codes nationaux provinciaux et locaux applicables pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE s bap 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 br ler les yeux et la peau Le bruit caus par Portez des v tements en mat riaux ignifuges et durables laine certains proc d s peut endommager et cuir et des chaussures de s
72. or The auxiliary generator 15 self excited The voltage output furnishes 115 volt power to a diode bridge rectifier which provides DC voltage for exci tation of the auxiliary generator fields and welding generator fields It provides 115 volt and 230 volt AC power to the receptacles on the Control Panel for operation of small tools lights etc See Tabu lated Data for rated auxiliary power of your unit Engine The engine used in this unit is a Perkins Industrial 3 152 diesel engine lt 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 of the cylinder block When ordering spare parts or communicating about this machine be sure to specify the engine serial number engine type unit specification 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 en gine parts Tabulated Data Generator Output Auxiliary Power 3kVA 115 230V AC Output Welding Generator 12 kW Amperes rated 300 Amps Voltage 40
73. or lay it down on the ground or the work surface Do not power circuit and machine internal circuits are also ee a Poder Ma live when power is In semiautomatic or automatic 4 peop it wire welding the wire wire reel drive roll housing Do not use worn damaged undersized or poorly spliced cables and all metal parts touching the welding wire are Do not wrap cables around your body electrically live Incorrectly installed or improperly Ground the workpiece to a good electrical earth ground grounded equipment is a hazard Do not touch electrode while in contact with the work ground Do not touch live electrical parts circuit Wear dry hole free insulating gloves and body protection Use only well maintained equipment Repair or replace damaged Insulate yourself from work and ground using dry insulating mats parts at once or covers In confined spaces or damp locations do not use a welder with Disconnect input power or stop engine before installing or serv AC output unless it is equipped with a voltage reducer Use icing this equipment Lock input power disconnect switch open equipment with DC output or remove line fuses so power cannot be turned on accidentally Wear a safety harness to prevent falling if working above floor Properly install and ground this equipment according to its level Owner s Manual and national state and local codes Keep all panels and covers securely in place Touching
74. r less spatter type of welding arc Setting the Arc Force Control to DIGGING 6 to 10 range gives 5 2 December 1 1997 Revised 430429 231 OPERATION a very forceful driving 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 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 above instructions Operate unit with canopy doors closed 2 Set Range Selector Switch on desired range and adjust current control for desired current Turn ing the current control clockwise increases the weld ing 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 control handle IN towards the panel as far as it will go 3 Allow engine to cool sufficiently then check coolant and
75. s GIONTIOS 85 e n 2 ONTOS SIG Es PAD AA Sava mn S x NMOGINHS mys o H UM 1915 83H13 TWNOLdO f L doi 5 gt 22 MS JOMINOO 03345 305 MONJ 301430 3101 VOLVNYALTY v AU3LVE SK sot LIOA 21 AWALIVE g d3TIVISNI 2 29870087 S panva NIHA 2 23 a lt 03123NNO2SK Si SM 9 11 5 f ym se er 08 W30N3S 39nv9 1304 35 HOLIMS GIONT10S 39nvo Sos A MILVM JMNSSIUG 10 Wilwvis aunss3ua 9nd siid si IMVISOKUJHL xi ior 6 hr nec OITIVISNI SI 3935 ANS COF davis 43443 N3HM 39055344 10 g 031934405 38 1519 2 1 3 Lo t 4 i CL 1 HOIIMS 39nv9 8 auvaa ALINUNOH 1 i IET em t od WALINOHOVI SYAN 3NION3 TNOUdO m 387 1 1 f 6 l l l VENA re Lilas 3 z NMOGLNHS NOUD3NNOO 30010 VSN TLCS Var 13385 7 T c a DNUMvuO wow iW 50 xx ON 000 SOS C 09134 VIVO 34407730 NOIL23NNOO 7
76. sposal Method Lead acid batteries are completely recycable For information on returning batteries to East Penn for recycle call 610 682 6361 Precautions to be Taken in Handling and Storing Other P s 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 EAST PENN manufacturing co inc 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 Name s OSHA PEL ACGIH TLV Recommended Percent Lead CAS 47439921 0 05 mg m 0 15 mg m 43 70 Sulfuric Acid CAS 7664939 1 00 mg m 1 00 mg m 20 44
77. stablish 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 nat 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 Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet 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 C
78. the underlined specification or part numbers listed on the cover none are underlined they are all 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 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 to shipping If there is any damage notify the carrier immedi ately to file a claim Furnish complete information concerning damage claims or shipping errors to Thermal
79. um 1 8 to 1 2 in 3 12 mm Light Heavy Over 1 2 in 12 mm Heavy Shielded metal arc welding Under 5 32 in 4 mm Plasma arc cutting stick electrodes 5 32 to 1 4 in 4 to 6 4 mm Light Under 300 Amp Over 1 4 in 6 4 mm Medium 300 to 400 Amp Heavy Over 400 Amp May 8 1996 2 1 ARC 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 If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If 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 eguipment 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 flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas FLYING SPARKS A
80. ve 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 general 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 430429 231 DIAGRAMS 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 e Use only those diagrams and instructions that are applicable
81. y found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly 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 All parts of the equipment are listed except for commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded SPEC NUMBER 6298C 1 629DC 1 to another part The part descriptions may be indented 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 inthe 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

MEGA-ARC 4030D 30 Amp Constant Current Diesel

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