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Mega-Arc 4030D 30 Amp Constant Current Diesel Engine-Driven Welding Generator

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MEGA-ARC® 4030D

30 Amp Constant Current Diesel


Engine-Driven Welding Generator

For the Following Specs:


• 6298C-1
• 6298D-1

OWNER’S MANUAL Number 430429-231


Revised December 1, 1997

IMPORTANT: Read these instructions before installing, operating, or servicing this system.

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 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

SAFETY INSTRUCTIONS AND WARNINGS 2

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

December 1, 1997 Revised Page 1


430429-231
Table of Contents

TROUBLESHOOTING 7

PARTS LIST 8
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
How To Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

MATERIAL SAFETY DATA SHEET

DIAGRAMS

Page 2 December 1, 1997 Revised


430429-231
INTRODUCTION

INTRODUCTION

How To Use This Manual Receipt Of Equipment


This Owner’s Manual usually applies to just the When you receive the equipment, check it against
underlined specification or part numbers listed on the invoice to make sure it is complete and inspect
the cover. If none are underlined, they are all cov- the equipment for possible damage due to shipping.
ered by this manual. If there is any damage, notify the carrier immedi-
ately to file a claim. Furnish complete information
Throughout this manual, the words WARNING, concerning damage claims or shipping errors to
CAUTION, and NOTE may appear. Pay particular Thermal Arc, Order Department, 2200 Corporate
attention to the information provided under these Drive, Troy, Ohio 45373-1085. Include all equip-
headings. These special annotations are easily rec- ment identification numbers as described above
ognized as follows: 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
WARNING gives information re- top of the cabinet on most equipment to facilitate
garding possible personal in- handling with a hoist or crane. Use care to avoid
jury. Warnings will be enclosed damaging the equipment when using bars, ham-
in a box such as this. mers, etc., to uncrate the unit.

WARNING: Falling machine due


CAUTION refers to possible equipment
damage. Cautions will be shown in bold
to lifting eye failure may cause
type. death or serious injury.

• Lifting device may fail when overloaded.


NOTE offers helpful information concern- • This lifting device is designed to lift the
ing certain operating procedures. Notes will power source ONLY. If the machine is
be shown in italics. equipped with a trailer or accessories over
100 pounds, DO NOT LIFT by lifting eyes.
• Avoid sudden jerks, drops, or swinging.
Equipment Identification • Check lifting device components visually
for looseness and signs of metal fatigue.
The unit’s identification number (specification or • Before changing any hardware, check
part number), model, and serial number usually
grade and size of bolts, and replace with
appear on a nameplate attached to the control
bolts of equal or higher size and grade.
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- Additional copies of this manual may be pur-
blies are identified only by the specification or part chased by contacting Thermal Arc at the address
number printed on the shipping container. Record given above. Include the Owner’s Manual number
these numbers for future reference. 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 WARNINGS


ARC WELDING can be hazardous.

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

May 8, 1996 2-1


ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

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.

ENGINES can be hazardous.

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.

2-2 May 8, 1996


ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

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.

PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
Welding Society, 550 N.W. 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.

May 8, 1996 2-3


ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

This page intentionally left blank.

2-4 May 8, 1996


PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002

PRECAUTIONS DE SECURITE EN SOUDAGE A L′ARC


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 UN MEDECIN).
CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU
ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel
et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises
par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage
ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres
s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à
suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces
instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET
D’ESSAI.

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.

pour vous protéger le visage et les yeux lorsque vous soudez ou


que vous observez l’exécution d’une soudure.
LE RAYONNEMENT DE L′ARC PEUT 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
BRÛLER LES YEUX ET LA PEAU; LE sont recommandés.
BRUIT PEUT ENDOMMAGER L′OUIE.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour
L’arc de soudage produit une chaleur et des protéger les autres des coups d’arc ou de l’éblouissement;
rayons ultraviolets intenses, susceptibles de avertissez les observateurs de ne pas regarder l’arc.
brûler les yeux et la peau. Le bruit causé par 4. Portez des vêtements en matériaux ignifuges et durables (laine
certains procédés peut endommager l’ouïe. et cuir) et des chaussures de sécurité.
1. Portez une casque de soudeur avec filtre oculaire de nuance 5. Portez un casque antibruit ou des bouchons d’oreille approuvés
appropriée (consultez la norme ANSI Z49 indiquée ci-après) lorsque le niveau de bruit est élevé.

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 )

Opération Dimension d’électrode ou Nuance de


de Epaisseur de métal ou de filtre
Coupage ou soudage Intensité de courant oculaire
Brasage tendre au chalumeau toutes conditions 2
Brasage fort au chalumeau toutes conditions 3 ou 4
Oxycoupage
mince moins de 1 po. (25 mm) 2 ou 3
moyen de 1 à 6 po. (25 à 150 mm) 4 ou 5
épais plus de 6 po. (150 mm) 5 ou 6
Soudage aux gaz
mince moins de 1/8 po. (3 mm) 4 ou 5
moyen de 1/8 à 1/2 po. (3 à 12 mm) 5 ou 6
épais plus de 1/2 po. (12 mm) 6 ou 8
Soudage à l’arc avec moins de 5/32 po. (4 mm) 10
electrode enrobées (SMAW) de 5/32 à 1/4 po. (4 à 6.4 mm) 12
plus de 1/4 po. (6.4 mm) 14
Soudage à l’arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux toutes conditions 11
métaux ferreux toutes conditions 12
Soudage à l’arc sous gaz
avec électrode de tungstène (GTAW) toutes conditions 12
Soudage à l’hydrogène
atomique (AHW) toutes conditions 12
Soudage à l’arc avec
électrode de carbone (CAW) toutes conditions 12
Soudage à l’arc Plasma (PAW) toutes dimensions 12
Gougeage Air-Arc avec
électrode de carbone
mince 12
épais 14
Coupage à l’arc Plasma (PAC)
mince moins de 300 ampères 9
moyen de 300 à 400 ampères 12
épais plus de 400 ampères 14

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.

Le piquage et le meulage produisent des particules métalliques


volantes. En refroidissant, la soudure peut projeter du éclats de
LES ETINCELLES ET LES PROJEC- laitier.
TIO N S BRU LA NTES PEU V EN T
1. Portez un écran facial ou des lunettes protectrices approuvées.
CAUSER DES BLESSURES.
Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.

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.

LES MOTEURS PEUVENT ETRE DANGEREUX


LES GAZ D’ECHAPPEMENT DES 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et
MOTEURS PEUVENT ETRE MORTELS. bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
Les moteurs produisent des gaz d’échappement
fumées d’échappement doivent être envoyées à l’extérieur, loin
nocifs.
des prises d’air du bâtiment.

2. Ne faites pas le plein en fumant ou proche d’une source


d’étincelles ou d’une flamme nue.
LE CARBURANT PEUR CAUSER UN IN- 3. Si c’est possible, laissez le moteur refroidir avant de faire le
CENDIE OU UNE EXPLOSION. plein de carburant ou d’en vérifier le niveau au début du
Le carburant est hautement inflammable. soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
1. Arrêtez le moteur avant de vérifier le niveau de
l’espace pour son expansion.
carburant ou de faire le plein.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.

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.

PRINCIPALES NORMES DE SECURITE

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

Generator Tabulated Data


The Mega-Arc® diesel engine-driven arc welding Generator:
machine is a self-contained unit, mounted on a Output, Auxiliary Power .... 3kVA, 115/230V AC
welded steel frame. The unit is covered by a sheet
metal canopy, bolted directly to the frame. The Output, Welding Generator .....................12 kW
control panel is at the back (generator) end of the
Amperes, rated .................................300 Amps
unit.
Voltage, rated....................................... 40 Volts
The welding generator and auxiliary (exciter) gen-
erator revolving fields are mounted on a single Voltage, open-circuit ................. (max.) 75 Volts
heavy-duty shaft, supported by a ball bearing at the Duty Cycle, rated .....................................100%
exciter end of the shaft, and by the engine coupling
at the other end. Current Range ........ Low Range 15 to 200 A

The welding generator is 300 ampere @ 100% .................................High Range 30 to 400 A


duty cycle or 400 ampere @ 60% duty cycle, 3- Operating Speed....................See Engine Data
phase, wye connected, rectified to DC power by the
output rectifier, and stabilized by the stability reac- Engine:
tor. Make and model —
The auxiliary generator is self-excited. The AC ............................. Detroit Diesel/Perkins 3-152
voltage output furnishes 115-volt power to a diode
bridge rectifier which provides DC voltage for exci- Type ......................................... Industrial diesel
tation of the auxiliary generator fields and welding Displacement .................152 cu. in. (2.50 liters)
generator fields. It provides 115-volt and 230-volt
AC power to the receptacles on the Control Panel Brake horsepower.......... 38 BHP @ 1800 RPM
for operation of small tools, lights, etc. See Tabu- Oil sump capacity............. 7-1/2 quarts (7 liters)
lated Data for rated auxiliary power of your unit.
Cooling system capacity —
......................................... 9-1/2 quarts (9 liters)
Engine
Fuel tank capacity —
The engine used in this unit is a Perkins Industrial
3-152 diesel engine. It is directly coupled to the ............................ 17 gallons (U.S.) (64.4 liters)
welding generator shaft by a flexible coupling. Weight (dry) ..................... 463 pounds (210 kg)
Normal operating RPM .................... 1800 RPM
Identification Dimensions and Weight: (See Figure 4-1)
The welding generator unit has an identification
Width (doors closed) ......... 28 inches (711 mm)
plate attached to the control panel on the left-hand
side. The unit is identified as to SPEC number, by Width (doors open) ......... 77 inches (1956 mm)
the dash (—) number which follows it.
Length ...................... 61-1/2 inches (1562 mm)
The engine identification number is stamped on Height (top of canopy) —
right-hand side of the cylinder block. When ordering
spare parts, or communicating about this machine, ....................................... 40 inches (1016 mm)
be sure to specify the engine serial number, engine
Height (over eye in top) —
type, unit specification and serial numbers. Left- and
right-hand sides of the unit are determined when ....................................... 45 inches (1143 mm)
facing the control panel. See Supplementary Mate-
Weight (shipping) —
rials for address for communicating or ordering en-
gine parts. .......................... approx. 1600 pounds (726 kg)

December 1, 1997 Revised 3-1


430429-231
DESCRIPTION OF EQUIPMENT

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 OUT all the way for engine to run
Additional copies may be obtained from the manu- at rated RPM (1800). Push the handle IN 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 IN
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 in START position. Continue to hold it IN 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.
When engine is shut down, place switch in OFF CAUTION: Do not 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- unit (facing the control panel). See instructions in
sure drops to 3-5 psi for any reason. Initial Preparation for Use located in the Installation
chapter.
Alternator Light — Glows when engine alternator
circuit is not charging the battery at sufficient level. Auxiliary Power Receptacle — Duplex receptacles
located on the Control Panel (see Figure 3-1) fur-
Fuel Gauge — Indicates level of fuel in fuel tank.
nish 3-kVA, 115-volt and 230-volt, 60-Hz power.
Hour Meter — Indicates run time on engine.
NOTE: The output voltage will drop below
Water Temp. Gauge — Indicates coolant tempera- the rated volts when engine is in the idling
ture. mode. Low voltage may damage electrical
equipment connected to the generator
Generator Controls through this receptacle.
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 length 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 Figure 3-2 Weld Output Panel

December 1, 1997 Revised 3-3


430429-231
DESCRIPTION OF EQUIPMENT

Volt-Ampere Curve

3-4 December 1, 1997 Revised


430429-231
INSTALLATION

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.

11. Make sure that no loose bars, tools, parts, etc.,


CAUTION: A short circuit to rectifier is are in or on any part of engine as they could cause
created if a battery is installed with po- serious damage to or wreckage of engine or gener-
larity reversed. Current can flow from ator, or personal injury to anyone standing nearby.
positive terminal of battery through
negative and positive rectifiers and into 12. Carefully read and follow “Operating Instruc-
heat sink. From heat sink a completed 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)
Current 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet
Amperes (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 - #2/0
350 #3/0 #3/0 #3/0 2 - #2/0 2 - #3/0
400 #4/0 #4/0 #4/0 2 - #2/0 2 - #3/0

NOTE: Cable size shown is for 90°C (194°F) cable insulation, 30°C (86°F) ambient, and not over 4.5 volts
cable drop.

Table 4-1 Suggested Copper Welding Lead Size Guide

Figure 4-1 Dimensions

December 1, 1997 Revised 4-3


430429-231
INSTALLATION

This page intentionally left blank.

4-4 December 1, 1997 Revised


430429-231
OPERATION

OPERATION

WARNING: MA-4030D mounted on a trailer may develop a “rough” running


low idle. Normal idle speed is around 1300 RPM. When mounted on some
trailers, the unit will interact with the trailer leaf springs and tires and cause
it to run rough. To eliminate, adjust the idle screw on the injection pump (see
Figure 5-1) by turning either clockwise or counterclockwise to raise or lower
the low idle speed. Be sure, however, not to adjust the low idle below 1000
RPM as the generator will not operate properly.

Figure 5-1

Prestarting Instructions 2. Inspect the unit thoroughly to be sure it is in


In all probability, the welding unit will be moved proper working order. Check all fuel line and wire
from one location to another many times during its connections to be certain they are secure. Tighten
lifetime of service. Therefore, reference to Initial any loose screws, nuts or bolts.
Preparation For Use located in Installation chapter
3. Wipe off the entire unit and clean the air pas-
is suggested each time the unit is moved prior to
sages, control box and hard-to-reach places with
using it.
compressed air not over 25 psi (172 kPa).
1. Check the supply of fuel, crankcase oil and
radiator coolant. See Perkins Engine Handbook for 4. Make sure that no loose bars, tools, parts, etc.,
specifications. are in or on any part of the engine as they could
December 1, 1997 Revised 5-1
430429-231
OPERATION
cause serious damage to the engine, generator, or 5. Apply a load to the welding generator. This can
personal injury to anyone standing nearby. be accomplished by attaching a proper resistance
load across the welding terminals and setting the
5. If the unit is operated indoors, make sure that
current control. The load should be equal to at least
an exhaust line is properly connected to the engine
one-half of the normal full load output of the unit
exhaust system, and discharges out of doors. Avoid
(rated 300 amps/40 volts).
short bends or reduction in line size in exhaust
pipes, and locate the unit so as to necessitate the 6. Operate the engine-generator unit for approxi-
shortest possible exhaust line to insure the least mately one hour under the above loading condi-
amount of back-pressure on the engine. Back-pres- tions.
sure can cause engine damage and loss of power.
NOTE: This procedure can be followed at
6. Attach welding leads, as described under Initial
any time that wet-stacking becomes a prob-
Preparation For Use located in Installation chapter.
lem, in order to burn out the unburned
Observe Table 4-1 and determine that welding
hydrocarbons that accumulate in the ex-
leads are proper size for amperage being used for
welding. haust stack.

Break-in Procedures Prewelding Instructions


A proper break-in procedure for a new diesel en- To adjust weld current and arc characteristics
gine-driven welding generator is extremely impor- while welding, the High/Low Range Switch, Current
tant to avoid future problems. Long periods of Control, and Arc Force Control can all be adjusted
operation at idle or light load condition may result in under load, without damaging the welding ma-
cylinder wall “glazing” and resultant poor seating of chine. However, caution should be used in switch-
piston rings so that oil consumption will be exces- ing from low to high range on the Range Selector
sive. Also, it may result in “wet stacking”, which is Switch, as this would cause the welding current to
unburned fuel that accumulates in the exhaust pipe be immediately doubled. This might be more than
due to extremely low exhaust temperatures. The the electrode in use could stand. This would cause
following procedure will apply a load to the engine, immediate problems with the welding arc.
assuring the hot exhaust [at least 450°F (232°C)],
Note that on the Current Control dial, the low range
which will aid in preventing “wet stacking”.
is just one-half of the high range values. For exam-
1. Open the fuel shut-off valve at fuel tank. ple, leaving the Current Control setting constant, the
high range would deliver 200 amperes, and the low
2. Start the engine (see instructions under Engine
range 100 amperes. This relation holds consistent
Controls and Instruments included in Description of
through the entire range of the welding machine,
Equipment chapter) and let it idle for a few minutes
giving two widely overlapping current ranges.
to warm up lubricating oil and coolant, and then shut
The low range is 15 to 200 amperes, and the high
the engine off.
range is 30 to 400 amperes. The entire usable range
NOTE: Idling RPM is approximately 1300. of the machine for stick electrode (SMAW) welding
can be obtained in the single high range.
3. Check engine for low oil pressure, leaks or
malfunctioning parts. If oil pressure does not show Adjustable Arc Force control for the welding proc-
a sufficient, steady pressure within 5 seconds, shut ess gives the operator great flexibility in selecting
engine down and determine cause. the arc characteristics needed for a particular job.
(Refer to Volt-Amp Curves in Installation chapter.)
4. Start engine again. Pull throttle control handle
all the way OUT. Operate unit with canopy doors Setting the Arc Force Control at 4 to 6, or in the
closed. FORCEFUL range will adjust the welding charac-
teristics of the Mega-Arc® 4535D machine to be
NOTE: Covering the radiator partially with normal and similar to many of the conventionally
cardboard or plywood during this operating controlled engine-driven stick-electrode welding
period will speed up the engine warm-up. machines. However, turning down the Arc Force
Care must be taken, however, to avoid Control to the 2 to 4, or SMOOTH range, gives a
overheating and boiling the coolant in the softer, less “spatter” type of welding arc. Setting the
radiator. 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” 1. Clean up around working area. Put all tools,
the electrode nearly impossible. parts and supplies in their proper places.
Note on the Volt-Amp Curves that this adjustment 2. Disconnect welding leads from machine. Coil
of arc characteristics is accomplished by changing them and stow away in their place.
the short-circuit-to-welding current ratios as indi-
cated by the dotted lines for arc force settings of 0, 3. If unit is to be stored outdoors, it is wise to cover
2, 5, and 10 on the dial. it with a tarpaulin.
Extensive Storage Time — If unit is to be laid-up
for some time, please refer to Withdrawing An En-
Welding gine From Service, in Maintenance Section of
After all Prestarting and Break-In Procedures have Perkins Handbook for Diesel Engines, which is
been carried out, the controls for using the gene-ra- supplied with each unit.
tor for welding may be set and welding accom-
plished. Follow this procedure:
Adverse Weather Precautions
1. Start engine per above instructions. Operate Cold Weather Operation — Operation of engine-
unit with canopy doors closed. driven welding units at sub-zero temperatures re-
2. Set Range Selector Switch on desired range quires special precautions and extra servicing from
and adjust current control for desired current. Turn- both operation and maintenance personnel if poor
ing the current control clockwise increases the weld- performance or total functional failure is to be
ing current and open-circuit voltage; while turning it avoided. Consult Engine Workshop Manual and
counterclockwise decreases the welding current. recommendations below.

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.

5-4 December 1, 1997 Revised


430429-231
MAINTENANCE

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.

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-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.

No output at welding terminals (115-V and 230-V receptacle output OK).


Open circuit in welding generator revolving field coils.
Replace 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.

1. One SCR does not turn on (either it is open, or


Detailed Troubleshooting gate signal is not being received by the SCR [gate
Instructions circuit open]) and a very small change will occur at
The Mega-Arc® 4030D machines are solid-state the welding arc, and will be difficult to detect by the
welding machines. The method of troubleshooting average welding operator. Generally when this hap-
is different, but it is not more difficult than trou- pens, it will be necessary to adjust the current
bleshooting a conventional unit. Do not overlook the control on the front of the power source (see Figure
obvious. As in the case of all electrical equipment, 3-1), increasing the current to obtain the same
loose connections are the primary cause of mal- welding current that was being produced before the
function both internal and external to the power SCR defect occurred.
source. Do not overlook bad grounds, shorted con- Open-Circuit Voltage Test
trol cables, wrong settings, blown fuses, miscon-
nections from auxiliary equipment, misapplications, If the power source is suspected, a very simple
etc. The only equipment needed to properly detect test can tell you a great deal about the power
a problem on this power source is a simple vol- source. Observe the open-circuit voltage of the
tohmmeter, although an oscilloscope is the best machine by placing a voltmeter across the output
method to quickly “see” the problem. terminals. The voltage reading should be approxi-
mately 75 V DC.
Voltages — Refer to proper connection diagram.
See Diagram chapter included in this manual. If the voltage is not equal or close to 75 V DC, there
is something wrong with the power source (welding
The following voltages should be read at 1800 machine). Note that this voltage was observed at
RPM engine speed. normal engine speed (1800 RPM). It will vary ac-
1. Welding Generator phase-to-phase, on all three cording to the engine speed. If the 75 V DC is
phases — 60 V AC ± 10%. observed, there is a very good chance that the
power source is operating properly.
2. Phase-to-Neutral of Welding Generator —
35 V AC ±10%. NOTE: It is important to note that in the
LOW range (15 to 200 amperes) at mini-
3. Check for blown fuses F3-F8. Refer to Diagram mum setting of the Current Control, the
492107. Between wires 13 brown, 14 orange, 15 open-circuit voltage will drop to a lower
grey, 16 black, 17 yellow, and 18 blue on fuse block value and vary slightly with the current con-
— 60 V AC ±10%. trol. This is not a malfunction, but a normal
situation.
NOTE: The ± 10% value indicates the pos-
sibility of having a high or low engine RPM. Power Diode And SCR Testing
Malfunction In SCRs Or Diodes — The following In case of a severe malfunction such as a shorted
conditions will probably exist: 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, 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.

Isolating Malfunctioning SCR 2. Apply a thin coat of Alcoa #2 compound to


cleaned surface. Alcoa #2 is available from Thermal
This can be done best by trial-and-error method. Arc, part number 903870.
Use proper diagram as reference while inspecting
the unit. 3. Positively locate the SCR in place in the heat
sink. A small spring pin in the extruded heat sink will
On the output rectifier heat sink there are three locate the SCR.
SCRs, each having two small leads. The leads, a
white and red one, are connected to a wire harness 4. Place the clamp in position with the bolts
providing the gate signal to the SCRs. through the holes in the heat sink, and proceed in
following manner.
Turn the Current Control to maximum position
(fully clockwise) and begin disconnecting the white 5. Tighten the nuts evenly until finger tight.
leads from the harness, one at a time. As the first 6. Tighten each bolt in 1/4 turn increments using
lead is disconnected, observe the open-circuit volt- correct size hex key.
age of the machine. If the OCV drops to a lower
value, it will indicate that this particular SCR is 7. Place the Force Indicator Gauge (903878) firmly
working properly. Reconnect this lead, and proceed against the springs as shown. Be sure both ends
to do the same with the remaining two leads until and the center are in firm contact with the springs.
you discover which disconnection does not cause The gauge notch location will indicate the spring
the OCV to drop to a lower level. This will be the deflection or force. Correct mounting force is indi-
SCR which should be changed. cated as shown below.
Printed Circuit Board Testing 8. Spring deflection over 2-1/4 inches of spring is
.037" ± .002" for all clamps.
The next step is to check the Printed Circuit Board
inside the unit. See Figure 7-4 and Table 7-2 for 9. All clamps to be set at 4° mark. This corre-
location of test points and voltage values at the test sponds to the VE3000-VE2500 section on the
points. gauge label.

December 1, 1997 Revised 7-3


430429-231
TROUBLESHOOTING
Examples:

Less than rated Correct rated Excessive force.


force. Tighten force. L oo s en b o t h
nuts alternately nuts and start
1/4 turn at a 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 7-1 Figure 7-2

To Calibrate Force Gauge:


If the gauge is suspected of being out of calibration due to wear or damage, check it on a flat surface as
shown below.

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

Figure 7-4 Control P.C. Board

TEST TEST POINTS CALLOUTS VOLTAGE CONDITIONS REMARKS


1 TP-N to TP-E 2 to 13 +40.0/+21.0 1800 RPM/Idle No Load
2 TP-M to TP-E 14 to 13 –40.0/–21.0 1800 RPM/Idle No Load
3 TP-C to TP-E 3 to 13 +20.0 1800 or Idle No Load
4 TP-D to TP-E 12 to 13 –20.0 1800 or Idle No Load
5 TP-A to TP-E 4 to 13 +15.0 1800 or Idle No Load
6 TP-B to TP-E 11 to 13 –15.0 1800 or Idle No Load
7 TP-F to TP-E 5 to 13 +4.3 1800 or Idle No Load
TP-G to TP-E 7 to 13 +4.3 1800 or Idle No Load
TP-H to TP-E 9 to 13 +4.3 1800 or Idle No Load
8 TP-J to TP-E 6 to 13 +18.3 1800 or Idle No Load
TP-K to TP-E 8 to 13 +18.3 1800 or Idle No Load
TP-L to TP-E 10 to 13 +18.3 1800 or Idle No Load

Table 7-2

December 1, 1997 Revised 7-5


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TROUBLESHOOTING

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7-6 December 1, 1997 Revised


430429-231
PARTS LIST

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.

SPEC NUMBER APPLICATION NUMBER

6298C-1 A

629DC-1 B

December 1, 1997 Revised 8-1


430429-231
PARTS LIST

Figure 8-1 Control Panel

Parts List for Figure 8-1

Item Part Description Qty Application


No Number per Code
Assy
494119-4 Panel - Control Assembly 1 A
494119-7 Panel - Control Assembly 1
1 494096 . Panel - Control 1 A
494096-1 . Panel - Control 1 B
2 404089 . Receptacle - Duplex, 3 Wire, 230 V 1 All
3 403091-4 . Plug - Hole, Plastic 1 All
4 403091-12 . Plug - Hole, Plastic 1 All

8-2 December 1, 1997 Revised


430429-231
PARTS LIST
Parts List for Figure 8-1

Item Part Description Qty 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 2 All
8 Deleted
9 403091-2 . Plug - Hole, Plastic 1 All
10 30GH-1119 . Switch - Pushbutton 1 All
11 494134-1 . Gauge - Fuel 1 All
12 404856 . Switch - Toggle, DPDT, MOM, ON 1 All
13 405982-1 . Cover - Hole, Meter 2 All
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 - P.C. Board 6 All
20 491238 . . Board - P.C. Control Assembly 1 All
21 W-11166-9 . . Fuse - 1 Amp, Fast Blow 6 All
22 405129-1 . . Block - Fuse 1 All
23 367579 . . Insulator - Fuse Block 1 All
— 405157 . . Label - Fuse 1 All
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 All
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 K 2 All
29 492576 . . . Board - Mtg. 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

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430429-231
PARTS LIST

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8-4 December 1, 1997 Revised


430429-231
PARTS LIST
Parts List for Figure 8-1

Item Part Description Qty Application


No Number per Code
Assy

33 8BW-106A . . . Spacer 1 All


34 402682 . . . Switch - Toggle 2 All
35 400758 . . . Receptacle - 6 Pin Amphenol 1 All
36 404875 . . . Cap & Chain - Assembly 1 All
37 494097 Panel - Rear, Lower 1 A
494097-1 Panel - Rear, Lower 1 B
38 DW-4333 Rod - Throttle 1 All

— Not Illustrated

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
Parts List for Figure 8-2

Item Part Description Qty Application


No Number per Code
Assy

491461-2 Generator - Assembly 1 A


491461-6 Generator - Assembly 1 B
1 5J-260-0 . Cap - Bearing 1 A
5J-260-3 . Cap - Bearing 1 B
2 356773-38 . Housing - Exciter, Assembly 1 All
3 491897 . Armature 1 All
491464 . Brushholder - Assembly 1 All
4 491463 . . Bracket - Brushholder 1 All
5 402530 . . Guide - Brushholder 2 All
6 402788 . . Brush 2 All
7 402531 . . Cap - Brushholder 2 All
8 356773-42 . Housing - Gen. Assembly 1 All
9 491784 Ring - Adapter 1 All
10 491658-1 Fan & Coupling - Assembly 1 All
11 No Number Flywheel - (Supplied W/Engine) 1 All
12 492300-2 Housing - Flywheel 1 All
13 491758-1 Cover - Hole, Flywheel Housing 1 A
491758-3 Cover - Hole, Flywheel Housing 1 B
14 491813 Cover - Gen. Housing 1 A
491813-1 Cover - Gen. Housing 1 B
15 351683 Grommet - Lead Hole 2 All
16 491479 Cover - Exc. Housing 1 A
491479-1 Cover - Exc. Housing 1 B
17 C-31 Key - Coupling 1 All

December 1, 1997 Revised 8-7


430429-231
PARTS LIST

Figure 8-3 Generator Group

8-8 December 1, 1997 Revised


430429-231
PARTS LIST
Parts List for Figure 8-3

Item Part Description Qty Application


No Number per Code
Assy

1 492364-1 Top - Canopy 1 A


492364-3 Top - Canopy 1 B
2 409158 Label - Danger 1 All
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 Tank 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 All
28 405140-1 . Clamp - Mounting 3 All
29 492413 . Heat Sink - SCR 3 All

— 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 . Pin - Spring 3 All
31 494459-1 . Spacer - Insulating 2 All
32 410223-6 . Tubing - Fiber 2 All
33 494459-8 . 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 Rd. Hd. MH. 2 All
45 No Number . Washer - 1/2 FL. ST. 3 All
46 367687 . Shunt 1 All
— W-9234-338 Cable - Output Term. to Rect. 1 All
— 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 All

— Not Illustrated

December 1, 1997 Revised 8-11


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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 Qty Application


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 All
62 494128 Panel - Side, Right 1 A
494128-1 Panel - Side, Right 1 B
63 409554-1 Rectifier - Assembly 1 All
63A 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 Revised


430429-231
PARTS LIST
Parts List for Figure 8-3

Item Part Description Qty Application


No Number per Code
Assy

86 492133-4 Cable - Batt. Pos. 1 All


87 492132-3 Cable - Batt. Neg. 1 All
88 491962-1 Clamp - Battery 1 A
491962-2 Clamp - Battery 1 B
89 494295 Rods - Battery 2 All
90 491122 Angle - Mtg. 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 - Mtg. Gen. 1 B
93 406254-3 Mount - Shock 4 All
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 All
— 493797-2 Protector - Batt. Term. 1 All
— 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
Parts List for Figure 8-4

Item Part Description Qty Application


No Number per Code
Assy

492288-1 Line - Fuel & Return 1 All


1 490036 . Line - Fuel 1 All
2 W-10869-14 . Clamp - Hose 6 All
3 355325-10 . Hose - Rubber 1 All
4 355325-16 . Hose - Rubber 1 All
5 405091-1 . Elbow - Male, Barbed 1 All
6 402265 . Valve - 1/4 Turn, Shut Off 1 All
7 492075 . Line - Return 1 All
8 491889-4 . Hose - Rubber 1 All
9 402927-1 . Adapter - Tube to Pipe 1 All
9A 12CW-2125 . Elbow - Street, 45° 1 All

Speed Control Section

10 490186 Arm - Fuel Shut-Off 1 All


11 400562-32 Spring 1 All
12 490028 Pivot - Throttle 2 All
13 16DW-34 Bushing - Throttle 2 All
14 494541 Clamp - Throttle Rod 1 All
15 490010 Support - Throttle Rod 1 A
490010-1 Support - Throttle Rod 1 B
16 492360 Bracket - Spring 1 A
492360-1 Bracket - Spring 1 B
17 W-799F-110 Spring 1 All
— 490073 Bracket - Spring 1 A
— 490073-1 Bracket - Spring 1 B

— Not Illustrated

December 1, 1997 Revised 8-17


430429-231
PARTS LIST

This page intentionally left blank.

8-18 December 1, 1997 Revised


430429-231
DIAGRAMS

DIAGRAMS
• Note the model and specification number shown on the equipment nameplate.

• Locate these numbers in the model and specification number columns below.

• Use only those diagrams and instructions that are applicable.

CONTROL
MODEL SPECIFICATION CONNECTION BOX ENGINE
NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM

6298C-1 494148A 494699 494148A

Mega-Arc 4030D

6298D-1 494148A 494699 494148A

December 1, 1997 Revised


LOCAL LOCAL

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.

Thermal Arc Inc. Effective January 4, 1999


Troy, Ohio 45373 830538

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