Mega-Arc 4030D 30 Amp Constant Current Diesel Engine-Driven Welding Generator
Mega-Arc 4030D 30 Amp Constant Current Diesel Engine-Driven Welding Generator
Mega-Arc 4030D 30 Amp Constant Current Diesel Engine-Driven Welding Generator
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
INTRODUCTION 1
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Receipt Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
DESCRIPTION OF EQUIPMENT 3
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Supplementary Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Generator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
INSTALLATION 4
General Engine Driven Welder Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Indoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Portable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Initial Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Welding Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
OPERATION 5
Prestarting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Break-in Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Prewelding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Adverse Weather Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
MAINTENANCE 6
Engine And Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Inspection And Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exciter/Auxiliary Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Failure To Build Up Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
TROUBLESHOOTING 7
PARTS LIST 8
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
How To Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
DIAGRAMS
INTRODUCTION
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUC-
TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain
of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and
other 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. 6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
Touching live electrical parts can cause fatal shocks
7. Use fully insulated electrode holders. Never dip holder in water
or severe burns. The electrode and work circuit is
to cool it or lay it down on the ground or the work surface. Do not
electrically live whenever the output is on. The input
touch holders connected to two welding machines at the same
power circuit and machine internal circuits are also
time or touch other people with the holder or electrode.
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, 8. Do not use worn, damaged, undersized, or poorly spliced cables.
and all metal parts touching the welding wire are 9. Do not wrap cables around your body.
electrically live. Incorrectly installed or improperly 10. Ground the workpiece to a good electrical (earth) ground.
grounded equipment is a hazard.
11. Do not touch electrode while in contact with the work (ground)
1. Do not touch live electrical parts. circuit.
2. Wear dry, hole-free insulating gloves and body protection. 12. Use only well-maintained equipment. Repair or replace damaged
3. Insulate yourself from work and ground using dry insulating mats parts at once.
or covers. 13. In confined spaces or damp locations, do not use a welder with
4. 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. 14. Wear a safety harness to prevent falling if working above floor
5. Properly install and ground this equipment according to its level.
Owner’s Manual and national, state, and local codes. 15. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin; 1. Wear a welding helmet fitted with a proper shade of filter (see
NOISE can damage hearing. ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
Arc rays from the welding process produce intense 3. 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.
and skin. Noise from some processes can damage
4. Wear protective clothing made from durable, flame-resistant
hearing.
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Electrode Size Filter Electrode Size Filter
Welding or Cutting Metal Thickness Shade Welding or Cutting Metal Thickness Shade
Operation or Welding Current No. Operation or Welding Current No.
Torch soldering — 2 Gas metal-arc welding (MIG)
Torch brazing — 3 or 4 Non-ferrous base metal All 11
Oxygen cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 Atomic hydrogen welding All 12
Heavy Over 6 in., 150 mm 5 or 6 Carbon arc welding All 12
Gas welding Plasma arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Carbon arc air gouging
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Light 12
Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14
Shielded metal-arc welding Under 5/32 in., 4 mm 10 Plasma arc cutting
(stick) electrodes 5/32 to 1/4 in., 4 to 6.4 mm 12 Light Under 300 Amp 9
Over 1/4 in., 6.4 mm 14 Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
FUMES AND GASES can be hazardous 4. Read the Material Safety Data Sheets (MSDSs) and the manu-
to your health. facturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
Welding produces fumes and gases. Breathing these wearing an air-supplied respirator. Shielding gases used for
fumes and gases can be hazardous to your health. welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
1. Keep your head out of the fumes. Do not breath the fumes.
form highly toxic and irritating gases.
2. If inside, ventilate the area and/or use exhaust at the arc to
7. Do not weld on coated metals, such as galvanized, lead, or
remove welding fumes and gases.
cadmium plated steel, unless the coating is removed from the
3. If ventilation is poor, use an approved air-supplied respirator. weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
WELDING can cause fire or explosion. 5. Watch for fire, and keep a fire extinguisher nearby.
Sparks and spatter fly off from the welding arc. The 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
flying sparks and hot metal, weld spatter, hot work- can cause fire on the hidden side.
piece, and hot equipment can cause fires and burns.
7. Do not weld on closed containers such as tanks or drums.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire. 8. 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.
1. Protect yourself and others from flying sparks and hot metal.
9. Do not use welder to thaw frozen pipes.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. 10. Remove stick electrode from holder or cut off welding wire at
If this is not possible, tightly cover them with approved covers. contact tip when not in use.
4. Be alert that welding sparks and hot materials from welding can 11. Wear oil-free protective garments such as leather gloves, heavy
easily go through small cracks and openings to adjacent areas. shirt, cuffless trousers, high shoes, and a cap.
FLYING SPARKS AND HOT METAL can 1. Wear approved face shield or safety goggles. Side shields rec-
cause injury. ommended.
2. Wear proper body protection to protect skin.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
CYLINDERS can explode if damaged. 3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
Shielding gas cylinders contain gas under high pres- fittings designed for the specific application; maintain them and
sure. If damaged, a cylinder can explode. Since gas associated parts in good condition.
cylinders are normally part of the welding process,
6. Turn face away from valve outlet when opening cylinder valve.
be sure to treat them carefully.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
1. Protect compressed gas cylinders from excessive heat, mechani- 8. Read and follow instructions on compressed gas cylinders, asso-
cal shocks, and arcs. ciated equipment, and CGA publication P-1 listed in Safety
2. Install and secure cylinders in an upright position by chaining Standards.
them to a stationary support or equipment cylinder rack to prevent
falling or tipping.
ENGINE EXHAUST GASES can kill. 1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
Engines produce harmful exhaust gases. from any building air intakes.
ENGINE FUEL can cause fire or 2. Do not add fuel while smoking or if unit is near any sparks or open
explosion. flames.
3. Allow engine to cool before fueling. If possible, check and add
Engine fuel is highly flammable.
fuel to cold engine before beginning job.
1. Stop engine before checking or adding fuel. 4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
MOVING PARTS can cause injury. 3. Have only qualified people remove guards or covers for mainte-
Moving parts, such as fans, rotors, and belts can cut nance and troubleshooting as necessary.
fingers and hands and catch loose clothing. 4. To prevent accidental starting during servicing, disconnect nega-
tive (-) battery cable from battery.
1. Keep all doors, panels, covers, and guards closed and securely 5. Keep hands, hair, loose clothing, and tools away from moving
in place. parts.
2. Stop engine before installing or connecting unit. 6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES 1. Always wear a face shield when working on a battery.
TO EXPLODE; BATTERY ACID can 2. Stop engine before disconnecting or connecting battery cables.
burn eyes and skin. 3. Do not allow tools to cause sparks when working on a battery.
Batteries contain acid and generate explosive gases. 4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
STEAM AND PRESSURIZED HOT 1. Do not remove radiator cap when engine is hot. Allow engine to
COOLANT can burn face, eyes, and cool.
skin. 2. Wear gloves and put a rag over cap area when removing cap.
The coolant in the radiator can be very hot and under 3. 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 & 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 & Magnetic Fields — Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to
offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them. 3. Do not coil or drape cables around the body.
2. Arrange cables to one side and away from the operator. 4. Keep welding power source and cables as far away from body as
practical.
About Pacemakers:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, Code for Safety in Welding and Cutting, CSA Standard W117.2, from
D.C. 20402. 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- Safe Practices for Occupation and Educational Eye and Face Pro-
can Welding Society Standard AWS F4.1, from American Welding tection, ANSI Standard Z87.1, from American National Standards
Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire Cutting and Welding Processes, NFPA Standard 51B, from National
Protection Association, Batterymarch Park, Quincy, MA 02269. Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
L’E LE C T R OC UTION P E UT ETRE 6. Arrêtez tout équipement après usage. Coupez l’alimentation de
MORTELLE. l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
Une décharge électrique peut tuer ou brûler grave-
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
ment. L’électrode et le circuit de soudage sont sous
laisser traîner par terre ou sur les pièces à souder. Ne touchez
tension dès la mise en circuit. Le circuit d’alimenta-
pas aux porte-électrodes raccordés à deux sources de courant
tion et les circuits internes de l’équipement sont
en même temps. Ne jamais toucher quelqu’un d’autre avec
aussi sous tension dès la mise en marche. En
l’électrode ou le porte-électrode.
soudage automatique ou semi-automatique avec
fil, ce dernier, le rouleau ou la bobine de fil, le 8. N’utilisez pas de câbles électriques usés, endommagés, mal
logement des galets d’entrainement et toutes les épissés ou de section trop petite.
pièces métalliques en contact avec le fil de soudage 9. N’enroulez pas de câbles électriques autour de votre corps.
sont sous tension. Un équipement inadéquatement 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
installé ou inadéquatement mis à la terre est dangereux. de la pièce à souder.
1. Ne touchez pas à des pièces sous tension. 11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
2. Portez des gants et des vêtements isolants, secs et non troués. soudage (terre).
3. Isolez-vous de la pièce à souder et de la mise à la terre au moyen 12. N’utilisez que des équipements en bon état. Réparez ou rem-
de tapis isolants ou autres. placez aussitôt les pièces endommagées.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez 13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le de courant alternatif, à moins qu’il soit muni d’un réducteur de
commutateur en circuit ouvert ou enlevez les fusibles de l’alimen- tension. Utilisez plutôt une source de courant continu.
tation afin d’éviter une mise en marche accidentelle. 14. Portez un harnais de sécurité si vous travaillez en hauteur.
5. Veuillez à installer cet équipement et à le mettre à la terre selon 15. Fermez solidement tous les panneaux et les capots.
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.
8-V-96 2-1
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE
( selon AWS A 8.2-73 )
LES VAPEURS ET LES FUMEES SONT 5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
DANGEREUSES POUR LA SANTE. sinon, portez un respirateur à adduction d’air. Les gaz protec-
teurs de soudage peuvent déplacer l’oxygène de l’air et ainsi
Le soudage dégage des vapeurs et des fumées causer des malaises ou la mort. Assurez-vous que l’air est
dangereuses à respirer. propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
1. Eloignez la tête des fumées pour éviter de les respirer.
peuvent réagir avec des vapeurs et former des gaz hautement
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ven- toxiques et irritants.
tilée ou que les fumées et les vapeurs sont aspirées à l’arc.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
3. Si la ventilation est inadequate, portez un respirateur à adduc- cadmium que si les zones à souder ont été grattées à fond, que
tion d’air approuvé. si l’espace est bien ventilé; si nécessaire portez un respirateur
4. Lisez les fiches signalétiques et les consignes du fabricant à adduction d’air. Car ces revêtements et tout métal qui contient
relatives aux métaux, aux produits consummables, aux revête- ces éléments peuvent dégager des fumées toxiques au moment
ments et aux produits nettoyants. du soudage.
2-2 8-V-96
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
LE SOUDAGE PEUT CAUSER UN IN- 4. Méfiez-vous des projections brulantes de soudage susceptibles
CENDIE OU UNE EXPLOSION de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
L’arc produit des étincellies et des projections. Les
5. Méfiez-vous des incendies et gardez un extincteur à portée de
particules volantes, le métal chaud, les projections
la main.
de soudure et l’équipement surchauffé peuvent
causer un incendie et des brûlures. Le contact 6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
accidentel de l’électrode ou du fil-électrode avec un plancher, une cloison ou une paroi peut enflammer l’autre côté.
objet métallique peut provoquer des étincelles, un échauffement 7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
ou un incendie. 8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long par-
cours inconnu, et prévenir ainsi les risques d’électrocution et
1. Protégez-vous, ainsi que les autres, contre les étincelles et du d’incendie.
métal chaud.
9. Ne dégelez pas les tuyaux avec un source de courant.
2. Ne soudez pas dans un endroit où des particules volantes ou
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con-
des projections peuvent atteindre des matériaux inflammables.
tact lorsqu’inutilisé après le soudage.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
11. Portez des vêtements protecteurs non huileux, tels des gants
mètres autour de l’arc, ou couvrez-les soigneusement avec des
en cuir, une chemise épaisse, un pantalon revers, des bottines
bâches approuvées.
de sécurité et un casque.
LES BOUTEILLES ENDOMMAGEES 4. Empêchez tout contact entre une bouteille et une électrode de
PEUVENT EXPLOSER soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
Les bouteilles contiennent des gaz protecteurs
des boyauxs et des raccords conçus pour chaque application
sous haute pression. Des bouteilles endommagées
spécifique; ces équipements et les pièces connexes doivent
peuvent exploser. Comme les bouteilles font nor-
être maintenus en bon état.
malement partie du procédé de soudage, traitez-
les avec soin. 6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.
1. Protégez les bouteilles de gaz comprimé contre les sources de
7. Laissez en place le chapeau de bouteille sauf si en utilisation
chaleur intense, les chocs et les arcs de soudage.
ou lorsque raccordé pour utilisation.
2. Enchainez verticalement les bouteilles à un support ou à un
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
cadre fixe pour les empêcher de tomber ou d’être renversées.
comprimé et aux équipements connexes, ainsi que la publica-
3. Eloignez les bouteilles de tout circuit électrique ou de tout tion P-1 de la CGA, identifiée dans la liste de documents
soudage. ci-dessous.
8-V-96 2-3
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
DES PIECES EN MOUVEMENT PEU- 3. Seules des personnes qualifiées doivent démonter des protec-
VENT CAUSER DES BLESSURES. teurs ou des capots pour faire l’entretien ou le dépannage
nécessaire.
Des pièces en mouvement, tels des ventilateurs, des
4. Pour empêcher un démarrage accidentel pendant l’entretien,
rotors et des courroies peuvent couper doigts et
débranchez le câble d’accumulateur à la borne négative.
mains, ou accrocher des vêtements amples.
5. N’approchez pas les mains ou les cheveux de pièces en mou-
vement; elles peuvent aussi accrocher des vêtements amples
1. Assurez-vous que les portes, les panneaux, les capots et les et des outils.
protecteurs soient bien fermés. 6. Réinstallez les capots ou les protecteurs et fermez les portes
2. Avant d’installer ou de connecter un système, arrêtez le moteur. après des travaux d’entretien et avant de faire démarrer le
moteur.
DES ETINCELLES PEUVENT FAIRE EX- 1. Portez toujours un écran facial en travaillant sur un accumu-
P LOSER UN ACC UMU LATEUR; lateur.
L’ELECTROLYTE D’UN ACCUMU- 2. Arrêtez le moteur avant de connecter ou de déconnecter des
LATEUR PEUT BRULER LA PEAU ET câbles d’accumulateur.
LES YEUX. 3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
Les accumulateurs contiennent de l’électrolyte un accumulateur ou survolter momentanément un véhicule.
acide et dégagent des vapeurs explosives.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
LA VAPEUR ET LE LIQUIDE DE RE- 1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
FROIDISSEMENT BRULANT SOUS refroidi.
PRESSION PEUVENT BRULER LA 2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
PEAU ET LES YEUX. 3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
Le liquide de refroidissement d’un radiateur peut
être brûlant et sous pression.
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Safe Handling of Compressed Gases in Cylinders, document P-1,
Society, 550 N.W. LeJeune Rd., Miami, FL 33128. Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-
20402. ciation canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme Safe Practices for Occupation and Educational Eye and Face Pro-
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., tection, norme ANSI Z87.1, American National Standards Institute,
Miami, FL 33128. 1430 Broadway, New York, NY 10018.
National Electrical Code, norme 70 NFPA, National Fire Protection Cutting and Welding Processes, norme 51B NFPA, National Fire
Association, Batterymarch Park, Quincy, MA 02269. Protection Association, Batterymarch Park, Quincy, MA 02269.
2-4 8-V-96
430429-231
DESCRIPTION OF EQUIPMENT
DESCRIPTION OF EQUIPMENT
Volt-Ampere Curve
INSTALLATION
General Engine Driven Welder the shipping skid. No special precautions are re-
quired.
Installation
The frame of an engine driven welder is intended
to be a base to held the welder components to- Location
gether. This frame is not intended to be the primary For best operating characteristics and longest unit
structure of a trailer or wagon. This welder is in- life, take care in selecting an installation site. Avoid
tended to be installed on a rigid, flat surface. This locations exposed to high humidity, dust, high am-
surface must allow the weight of the welder to be bient temperature, or corrosive fumes. Moisture can
distributed evenly along the length of the welder condense on electrical components, causing corro-
frame. sion or shorting of circuits. Dirt on components
Never install any vibration isolation material (shock helps retain this moisture and also increases wear
mounts, etc.) beneath the welder frame. This could on moving parts.
defeat the engine/generator shock mounts and
cause abnormal vibration throughout the welder and Safety
produce vibration related problems.
Refer to additional installation instructions under
Before choosing an installation location, make the Safety Warnings chapter included in this man-
note of where the service items are located on the ual.
welder (oil change/fill, battery, air filter, fuel fill, etc.)
Install the welder for best access to the important
service items. Allow sufficient room for cooling air Indoor Installation
intake and exhaust. Adequate air circulation is needed at all times in
If you are unsure about any installation consult the order to assure proper operation. Provide at least
factory. 24 inches (610 mm) of space at radiator end of unit.
Make sure that ventilation openings are not ob-
Trailer Installation: Do not use the frame assem- structed. Allow ample space to open canopy doors
bly of this welder as the frame of a trailer (do not on sides of the unit (see Tabulated Data in Descrip-
attach axles or tongues directly to this frame). When tion of Equipment chapter for dimensions) for serv-
a trailer is required, use only trailers with its own icing, and space at the control panel end of unit for
support frame that has a gross weight rated to carry operation.
the weight of the welder and any other components
If unit is to be operated inside a building, make
mounted on the trailer. Be sure the trailer tires are
certain there is adequate ventilation to carry off
for use with trailers. The soft sidewall design used
escaping exhaust fumes and to provide an ample
in radial tires can cause vibration related problems.
supply of oxygen.
Be sure welder frame and trailer frame are electri-
cally bonded together. Place unit so that exhaust fumes are carried out of
the building using the shortest exhaust pipe possi-
Truck Bed Installation: When installing this ble and one with the fewest possible number of
welder on the bed of a truck allow the welder to sit bends. Exhaust back pressure can seriously affect
flat on the bed, or a surface which completely con- engine efficiency.
tacts the bottom of the welder frame. Do not modify
the welder frame by cutting or otherwise damaging All exhaust connections must be gastight.
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) Portable Installation
between the welder and the truck bed. Be sure For portable use, the machine may be located
welder frame and truck frame are electrically within 12 inches (305 mm) of a truck cab, panel, or
bonded together. whatever, if it is to be operated in the open air.
Ground Installation: The welder will operate per- The engine of the welding machine must be placed
fectly fine just sitting on the ground, with or without at the tongue end of the portable mounting for
December 1, 1997 Revised 4-1
430429-231
INSTALLATION
proper balance. If leads, etc., are to be stored on the circuit exists back to negative battery
unit, they must be forward of the axle to maintain terminal. Full battery voltage will be im-
proper balance of loading on the tongue end of the pressed on rectifiers, in the alternator.
unit. The resulting high current will damage
rectifiers and/or wiring harness.
NOTE: The unit should be operated in as
near a normal horizontal position as possi- 6. Fill fuel tank with grade of fuel recommended by
ble and never at a tilt greater than 10° engine manufacturer. (Consult engine instruction
sideways and/or 7° maximum, rear down. manual.) Be sure fuel is free of WATER and other
foreign matter. Make sure air vent to fuel tank is
open. See Safety Warnings chapter included in this
Initial Preparation For Use manual for precautions necessary when filling the
1. Open canopy doors on sides of engine. tank.
CAUTION: The canopy doors may fall to 7. Check to be sure that radiator is full (about 1"
a closed position during operation of the below neck). If not, add enough coolant (50/50 mix
unit if it is resting on an inclined surface, of water and antifreeze) to fill.
or for other reasons. Tie the doors to
each other, to lifting eye or fuel filler cap. 8. Pull the dipstick and check the oil level in
Failure to do so may result in injury to crankcase. If it is necessary to add oil, fill to dipstick
operating personnel. mark with correct seasonal grade of quality deter-
gent oil. See engine operator’s manual for recom-
2. Inspect unit thoroughly to be sure it is in proper mended viscosity and temperature chart (unit is
working order. Check all fuel and wire connections shipped with SAE 10W30 oil installed).
to be certain they are secure. Tighten any loose
screws, nuts, or bolts. Check closely for any dam- 9. After engine has been properly prepared for
age which may have occurred in transit. use, start the engine, and allow it to idle for 30
minutes or so. Carefully check again for any leaks
3. Remove all special tags from the machine, read or loose connections during this period.
carefully and follow any special directions they may
carry. Keep tags with manual for future reference. 10. Determine which welding polarity will be suit-
able for the welding job to be done.
4. Make certain that all radiator air passages and
cooling fins are free from foreign matter. Use clean, a. For STRAIGHT polarity (DCEN) attach ELEC-
dry compressed air to blow dirt and dust out of TRODE lead (leading to electrode holder) to the
cooling passages and control cabinet, 25 psi (172 NEGATIVE (—) terminal on the Terminal and Re-
kPa) maximum pressure. ceptacle Panel. Attach the WORK lead (with clamp
on end) to POSITIVE (+) terminal.
5. Attach battery cables to poles of battery as
indicated on wiring diagram. The negative (—) pole b. For REVERSE polarity (DCEP) attach ELEC-
should be grounded to the frame of the unit in a TRODE lead (leading to electrode holder) to the
secure manner. POSITIVE (+) terminal. Attach the WORK lead (with
clamp on end) to the NEGATIVE (—) terminal.
WARNING: Connect proper bat-
CAUTION: Do not change welding leads
tery cable clamp to the positive while generator is running, as open-cir-
(+) battery post first, then the cuit voltage (80 volts) is furnished to the
other cable clamp to the nega- terminals. Shut engine down to change
tive (—) post. leads.
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.
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.
OPERATION
Figure 5-1
3. Strike an arc and begin welding. If a change in a. Fuel System — Keep system clean and free
welding current is desired, increase by turning knob from water which may collect in a low spot in the fuel
clockwise until desired current is obtained. See line and freeze, plugging the line. Fuel tanks should
Prewelding Instructions above for details on current be kept FULL to prevent water condensation from
range, current level, and arc force control. the air above the fuel. Check the filter bowl daily for
presence of water.
b. Fuel — Keep fuel storage tanks or drums as
Stopping The Engine full as possible to avoid condensation of moisture
1. Stop welding. from the air above the fuel. After filling or moving
fuel containers, allow fuel to settle before using.
2. Push the throttle control handle IN towards the Never draw fuel from the extreme bottom of the
panel as far as it will go. container. Strain all fuel to remove any foreign
3. Allow engine to cool sufficiently, then check matter. When operating outdoors, take steps to
coolant and crankcase oil level. If engine oil is to be prevent the entry of snow, water and ice into the fuel
changed, it can be done most effectively while en- containers.
gine is still warm. c. Cooling System — Prior to cold weather,
drain ad flush the cooling system to remove accu-
CAUTION: Use extreme care when re-
mulations of rust and sediment. Mix and add anti-
moving a radiator cap from an over-
freeze solution, check the cooling system
heated engine. Turn the cap only to the
connections for leaks. Add a can of rust inhibitor to
first notch, and allow steam to escape
the radiator when system is winterized. This will
before removing the cap completely.
keep system cleaner and furnish lubrication for the
4. After engine has cooled completely, fill the fuel water pump.
tank. See Safety Warnings chapter included in this d. Lubrication — Drain the crankcase (prefer-
manual for precautions that should be taken when ably when warm after running) and fill with a lighter
filling the fuel tank. grade of oil. See Engine Oil Recommendations
chart in the Maintenance and Operator’s Manual for
recommended viscosity oil for various atmospheric
Storage temperatures. In cold weather, drain oil more fre-
Nightly — After operation, the following steps quently. Water condenses and collects quickly,
should be taken before storing the welding machine mixes with the oil and increases deposits to form a
for short periods of time. sludge. Check oil frequently for this condition. Water
December 1, 1997 Revised 5-3
430429-231
OPERATION
in crankcase or oil lines may freeze and cause c. Crankcase — The crankcase oil level will
serious damage to the oil pump, or shut off the oil bear close attention. Dusty conditions tend to load
supply. crankcase oil with dirt. Watch for dirty and gritty oil
conditions, and change oil more frequently as re-
e. Battery — Battery efficiency decreases
quired.
sharply with lower temperatures. Maintain the spe-
cific gravity of the battery between 1.275 and 1.300 Operation In Salt Water Areas
(fully charged condition). Make sure of full charge
a. Canopy — Wash canopy regularly to remove
before attempting to start engine in sub-zero condi-
salt film. Repaint any damaged places and oil the
tions.
side panel hinges regularly.
Operation In Hot And Humid Conditions b. Covering — To protect the engine and gen-
a. Cooling System — Elevate welding machine erator as much as possible from salt water atmos-
6 to 8 inches (150 to 200 mm) above floor or ground phere, keep the side panels on the canopy closed,
level to provide adequate circulation of air. Maintain when not in use. It is advisable to keep the unit
a more frequent check of the coolant level in the covered with a tarpaulin, if available, while not in
radiator. operation. Salt water should be wiped from the
engine, and all terminals and connections in the
b. Battery — The specific gravity and proper electrical system wiped dry. Keep all linkage oiled.
level of the battery electrolyte should be maintained.
Observe recommendations in the Maintenance and c. Brushes — The brushes of the welding gen-
Operator’s Engine Manual for proper care of the erator and exciter should be inspected regularly to
battery. make certain that they are free in the holders. Lift
the brushes in the brushholders about every two
Operation In Extremely Dusty Conditions — If days, to insure their freedom to slide within the
unit is to be operated under dusty, out-of-door con- holder. Wipe dry all the parts that can be reached,
ditions, place in a sheltered area. Take advantage and use compressed air, if available, to dry the parts
of any natural barriers which may offer protection of the generator that cannot otherwise be reached.
from blowing dust. If the installation is more than See Maintenance chapter for brush and commuta-
temporary, erect a protection shield. tor care.
a. Fuel System — Drain the fuel water-trap d. Field Coils — The fields should be dried as
sediment bowl frequently, and keep all fuel contain- thoroughly as possible. If they have become damp,
ers covered and protected against dust entry. proceed with recommended procedure in Mainte-
nance chapter.
b. Oil Filter and Air Cleaner — These both need
more frequent attention under dusty conditions. e. Battery Terminals — Thoroughly clean the
Check air cleaner daily. Replace oil filter cartridge battery terminals and connections. Coat terminals
as needed. Change element in the air cleaner as and connections with petroleum jelly to retard cor-
required. rosion.
MAINTENANCE
Engine And Related Components 2. Lift brush (D) from brushholder (C) for inspec-
tion. If brushes are worn unevenly or are shorter
NOTE: Check Detroit Diesel/Perkins Hand- than 7/16 inch (11 mm), replace them.
book for Diesel Engines for all engine-re-
lated maintenance. 3. Inspect slip rings whenever brushes are re-
moved for servicing brushes or brushholders. Note
surface condition of rings. Surface should appear
Inspection And Cleaning smooth and clean. Scoring or roughness of slip
Every Day, check for oil, coolant, or fuel leaks. rings may be caused by grit or abrasive substance
Also check for loose electrical connections. Check in brushes, or by oil on the rings. Moderately rough
oil pressure with engine running at rated RPM (1800 slip rings can be smoothed by holding grade 00 flint
RPM). Do not operate engine if oil pressure light paper against their surface while the rings are re-
stays ON. Wipe accumulated water off all electrical volving slowly. If the rings are badly scored, the unit
connections and instruments. Make sure that the must be sent to an overhaul facility for repair. After
alternator light is not glowing, which indicates bat- cleaning slip rings, blow dirt and grit out of the unit
tery is being fully charged. with compressed air. Do not use over 25 psi (172
kPa) air pressure to blow dirt out.
Every Week, wipe accumulated dust, dirt, and oil
off from the engine and generator. Check all parts 4. Slip new brushes into brushholder guides, and
for looseness and wear. If arcing has occurred at place caps on top, and screw them into the guides
any electrical connection, recondition it and se- to a “bottomed” position. The spring attached to the
curely refasten. Check engine oil and coolant levels. brush will determine the pressure at which the brush
contacts the slip rings.
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 should not exceed
194°F (90°C).
Pound out any dents in the canopy. Sand, prime,
or repaint any dented or rusted spots.
Lubrication
Engine — Consult Perkins Handbook for Diesel
Engines.
Exciter/Auxiliary Brushes
(See Figure 6-1)
1. Disconnect leads (A) from connectors on brush-
holder caps (B).
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 Figure 6-1 Exciter/Auxiliary Brushes
proper brushes.
December 1, 1997 Revised 6-1
430429-231
MAINTENANCE
5. To fit new brushes to the slip rings, lay a strip of (CR1) diode bridge for a shorted diode which would
No. 00 sandpaper, smooth side down, on slip ring not allow unit to build up. If this check does not solve
surface, and draw the sandpaper in the direction of problem, check the revolving fields for continuity, as
rotation of the slip rings, lifting the brush on the explained below. See Figure 6-2.
return stroke. Continue until the brushes have the
same curvature as the slip rings. Blow all carbon To check for revolving field coil problems, it is
dust out of the machine using not over 25 psi (172 necessary to understand that there are two field
kPa) air pressure. circuits permanently paralleled at the slip ring con-
nections. A good armature will show 9-ohms resis-
Failure To Build Up Voltage tance measured at the slip rings (with brushes lifted
from rings). If the resistance measured at the rings
Refer to Connection Diagram in Diagrams chapter
is 12 ohms, then the exciter revolving fields (32-ohm
included in this manual.
coils) have an open circuit. If the measured resis-
One common problem with engine-driven gener- tance at the slip rings is 32 ohms, then the exciter
ators is failure to build up voltage from loss of fields (12 ohms) have an open circuit. A resistance
residual magnetism in the fields. measurement of much less than 9 ohms at the slip
Check all wiring from the exciter stator T1-T2 to rings indicates that there is a short circuit some-
rectifier (CR1) and to slip rings (SR). Also check where in the revolving field windings.
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
No output at 115-V 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.
Engine
See Detroit Perkins Handbook For Diesel Engines.
leads from the generator to the rectifier assembly, The following conditions indicate the possibility of
and check with a VOM for shorted SCRs and di- a defective P.C. Board:
odes.
1. Loss of welding arc completely.
An open gate or an open SCR cannot be checked
with a VOM. If an SCR is not firing, the open-circuit 2. Rough, sputtering arc, very noticeable.
voltage will shift down. Check the following table for
3. Loss of welding arc control.
typical values for a Mega-Arc® 4030D unit.
4. Difficulty in starting arc.
All Three
SCRs One Not Two Not Not If any voltage measurement does not agree with
Firing Firing Firing Firing Table 7-2 voltage values, the P.C. Board is probably
Max defective.
OCV 75 V DC 50 V DC 25 V DC 0 V DC
NOTE: Do not attempt to repair or recali-
brate these voltages, as they are factory
set.
Table 7-1
Mounting Procedure for SCRs
NOTE: The above values in Table 7-1 were 1. Thoroughly clean heat sink surface to eliminate
recorded at normal engine RPM (1800). any dirt or contamination.
If the calibration edges do not line up, calibrate the gauge by filing the bottom contact points.
Figure 7-3
Table 7-2
PARTS LIST
to another part. The part descriptions may be
Equipment Identification indented to show part relationships.
All identification numbers as described in the In-
troduction chapter must be furnished when ordering To determine the part number, description, quan-
parts or making inquiries. This information is usually tity, or application of an item, simply locate the item
found on the nameplate attached to the equipment. in question from the illustration and refer to that
Be sure to include any dash numbers following the item number in the corresponding Parts List.
Specification or Assembly numbers.
An “Application Code” is used to distinguish parts
that are applicable only to certain Specifications
How To Use This Parts List and/or Assemblies. This code is found in the right-
The Parts List is a combination of an illustration most column of the Parts List. If an item in the Parts
(Figure Number) and a corresponding list of parts List applies to all Specifications or Assemblies, the
which contains a breakdown of the equipment into word “ALL” will be in the Application Code column.
assemblies, subassemblies, and detail parts. All Refer to the following list to determine the appro-
parts of the equipment are listed except for commer- priate Application Codes for the Specifications or
cially available hardware, bulk items such as wire, Assemblies covered by this manual. If only the
cable, sleeving, tubing, etc., and permanently at- assembly or specification number is listed, the use
tached items which are soldered, riveted, or welded of an Application Code does not apply to this
manual.
6298C-1 A
629DC-1 B
— Not Illustrated
— Not Illustrated
— Not Illustrated
— Not Illustrated
— Not Illustrated
— Not Illustrated
— Not Illustrated
DIAGRAMS
• Note the model and specification number shown on the equipment nameplate.
• Locate these numbers in the model and specification number columns below.
CONTROL
MODEL SPECIFICATION CONNECTION BOX ENGINE
NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM
Mega-Arc 4030D
REMOTE REMOTE
STATEMENT OF WARRANTY
®
LIMITED WARRANTY: Thermal Arc , Inc., A Thermadyne Company, warrants that its products will be free of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated
below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized 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 consequential 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.
PURCHASER’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 & ROTATING) 3 YEARS 2 YEARS 1 YEAR
ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR
CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR
BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOID, PUMPS, POWER SWITCHING SEMI-CONDUCTORS
ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE 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.