You are on page 1of 58

Heavy Duty CC/CV

Semiautomatic Solid-State Control
Wire Feeder Model 2460
For the Following Specs:
• 6877A-1 4-Roll Drive, 40-600 IPM

6877B-1 4-Roll Drive, 40-600 IPM

6877A-2 4-Roll Drive, 20-300 IPM

6877B-2 4-Roll Drive, 20-300 IPM
OWNER’S MANUAL Number 430429-249 (Rev - AC)
Revised April 14, 2005
THERMAL ARC INC., W. LEBANON, NH 03784, USA
IMPORTANT: Readtheseinstructionsbeforeinstalling, operating, or servicingthissystem.
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
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Current Capacity and Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Feedhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Wire Reel Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
OPERATION 4
Prewelding Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
PARTS LIST 5
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
How To Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
How To Select Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CONTROL BOX ASSEMBLY NO. 376783A & 376783B TIP-218
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4 TIP-219
PARTS LIST FOR ASSEMBLY NO. 376799A-1, -2, -3, -4 MPL-224
BASE ASSEMBLY PART NO. 375769-1 & -4 TIP-127
WIRE SPOOL SUPPORT I-169
DIAGRAMS
430429-249
Table of Contents
December 1, 1997 Revised
April14, 2005 Revised 1-1
430429-249
INTRODUCTION
INTRODUCTION
How To Use This Manual
This Owner’s Manual usually applies to just the under-
lined specification or part numbers listed on the cover. If
none are underlined, they are all covered by this manual.
To ensure safe operation, read the entire manual, includ-
ing the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular atten-
tion to the information provided under these headings.
These special headings are easily recognized as
follows:
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
A NOTE offers helpful information concerning cer-
tain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
given in the next section. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the Ther-
mal Arc web site listed below and clicking on the Litera-
ture Library link:
http://www.thermadyne.com/tai
Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the control panel. In some cases,
the nameplate may be attached to the rear panel. Equip-
ment which does not have a control panel such as gun
and cable assemblies is identified only by the specifica-
tion or part number printed on the shipping container.
Record these numbers for future reference.
Receipt Of Equipment
When you receive the equipment, check it against the in-
voice to make sure it is complete and inspect the equip-
ment for possible damage due to shipping. If there is any
damage, notify the carrier immediately to file a claim. Fur-
nish complete information concerning damage claims or
shipping errors to:
Thermadyne, Inc.
Thermal Arc Order Department
82 Benning Street
West Lebanon, New Hampshire, USA 03784
For more information, call (603) 298-5711.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before uncrating
the unit. Use care to avoid damaging the equipment when
using bars, hammers, etc., to uncrate the unit.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERSKEEPAWAYUNTIL CONSULTINGYOURDOCTOR. DONOT LOSETHESEINSTRUCTIONS. READOPERATING/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.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live whenpower is on. Insemiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself fromwork and ground using dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or serv-
icing this equipment. Lock input power disconnect switch open,
or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
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.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
ARC WELDING can be hazardous.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Torch soldering
Torch brazing
Oxygen cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc welding
(stick) electrodes
Welding or Cutting
Operation
Gas metal-arc welding (MIG)
Non-ferrous base metal
Ferrous base metal
Gas tungsten arc welding (TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode Size
Metal Thickness
or Welding Current


Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in., 4 to 6.4 mm
Over 1/4 in., 6.4 mm
Electrode Size
Metal Thickness
or Welding Current
All
All
All
All
All
All
Under 300 Amp
300 to 400 Amp
Over 400 Amp
Filter
Shade
No.
2
3 or 4
3 or 4
4 or 5
5 or 6
4 or 5
5 or 6
6 or 8
10
12
14
Filter
Shade
No.
11
12
12
12
12
12
12
14
9
12
14
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
May 8, 1996 2-1
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work-
piece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
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.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
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.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
FLYINGSPARKSANDHOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields rec-
ommended.
2. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pres-
sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
1. Protect compressed gas cylinders fromexcessiveheat, mechani-
cal shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
themto a stationary support or equipment cylinder rack toprevent
falling or tipping.
3. Keep cylinders away fromany 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
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, asso-
ciated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manu-
facturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
2-2 May 8, 1996
STEAM AND PRESSURI ZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That HaveHeld Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosivegases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for mainte-
nance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect nega-
tive (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open
flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
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.
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:
About Pacemakers:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away from body as
practical.
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.)
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
May 8, 1996 2-3
This page intentionally left blank.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
2-4 May 8, 1996
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTSS’APPROCHER, NI LESPORTEURSDESTIMULATEURCARDIAQUE(AMOINSQU’ILSN’AIENTCONSULTEUNMEDECIN).
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’ ELECTROCUTI ON PEUT ETRE
MORTELLE.
Une décharge électrique peut tuer ou brûler grave-
ment. L’électrode et le circuit de soudage sont sous
tension dès la mise en circuit. Le circuit d’alimenta-
tion et les circuits internes de l’équipement sont
aussi sous tension dès la mise en marche. En
soudage automatique ou semi-automatique avec
fil, ce dernier, le rouleau ou la bobine de fil, le
logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage
sont sous tension. Un équipement inadéquatement
installé ou inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3. Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de l’alimen-
tation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Nejamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant
en même temps. Ne jamais toucher quelqu’un d’autre avec
l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou rem-
placez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
PRECAUTIONS DE SECURITE EN SOUDAGE A L

ARC
LE SOUDAGE A L′ARC EST DANGEREUX
LE RAYONNEMENT DE L′ARC PEUT
BRÛLER LES YEUX ET LA PEAU; LE
BRUIT PEUT ENDOMMAGER L′OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après)
pour vous protéger le visage et les yeux lorsque vous soudez ou
que vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arc ou de l’éblouissement;
avertissez les observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine
et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
8-V-96 2-1
SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE
( selon AWS A 8.2-73 )
Opération
de
Coupage ou soudage
Brasage tendre au chalumeau
Brasage fort au chalumeau
Oxycoupage
mince
moyen
épais
Soudage aux gaz
mince
moyen
épais
Soudage à l’arc avec
electrode enrobées (SMAW)
Soudage à l’arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
métaux ferreux
Soudage à l’arc sous gaz
avec électrode de tungstène (GTAW)
Soudage à l’hydrogène
atomique (AHW)
Soudage à l’arc avec
électrode de carbone (CAW)
Soudage à l’arc Plasma (PAW)
Gougeage Air-Arc avec
électrode de carbone
mince
épais
Coupage à l’arc Plasma (PAC)
mince
moyen
épais
Dimension d’électrode ou
Epaisseur de métal ou
Intensité de courant
toutes conditions
toutes conditions
moins de 1 po. (25 mm)
de 1 à 6 po. (25 à 150 mm)
plus de 6 po. (150 mm)
moins de 1/8 po. (3 mm)
de 1/8 à 1/2 po. (3 à 12 mm)
plus de 1/2 po. (12 mm)
moins de 5/32 po. (4 mm)
de 5/32 à 1/4 po. (4 à 6.4 mm)
plus de 1/4 po. (6.4 mm)
toutes conditions
toutes conditions
toutes conditions
toutes conditions
toutes conditions
toutes dimensions
moins de 300 ampères
de 300 à 400 ampères
plus de 400 ampères
Nuance de
de filtre
oculaire
2
3 ou 4
2 ou 3
4 ou 5
5 ou 6
4 ou 5
5 ou 6
6 ou 8
10
12
14
11
12
12
12
12
12
12
14
9
12
14
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ven-
tilée ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduc-
tion d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux revête-
ments et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz protec-
teurs de soudage peuvent déplacer l’oxygène de l’air et ainsi
causer des malaises ou la mort. Assurez-vous que l’air est
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
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
si l’espace est bien ventilé; si nécessaire portez un respirateur
à adduction d’air. Car ces revêtements et tout métal qui contient
ces éléments peuvent dégager des fumées toxiques au moment
du soudage.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
2-2 8-V-96
LE SOUDAGE PEUT CAUSER UN IN-
CENDIE OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections
de soudure et l’équipement surchauffé peuvent
causer un incendie et des brûlures. Le contact
accidentel de l’électrode ou du fil-électrode avec un
objet métallique peut provoquer des étincelles, un échauffement
ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou
des projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de
la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
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
d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con-
tact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants
en cuir, une chemise épaisse, un pantalon revers, des bottines
de sécurité et un casque.
LES ETINCELLES ET LES PROJEC-
TI ONS BRULANTES PEUVENT
CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules métalliques
volantes. En refroidissant, la soudure peut projeter du éclats de
laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées.
Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
LES BOUTEILLES ENDOMMAGEES
PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées
peuvent exploser. Comme les bouteilles font nor-
malement partie du procédé de soudage, traitez-
les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un
cadre fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent
être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation
ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publica-
tion P-1 de la CGA, identifiée dans la liste de documents
ci-dessous.
LES GAZ D’ ECHAPPEMENT DES
MOTEURS PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement
nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et
bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
LES MOTEURS PEUVENT ETRE DANGEREUX
LE CARBURANT PEUR CAUSER UN IN-
CENDIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le
plein de carburant ou d’en vérifier le niveau au début du
soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
8-V-96 2-3
DES PIECES EN MOUVEMENT PEU-
VENT CAUSER DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et
mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protec-
teurs ou des capots pour faire l’entretien ou le dépannage
nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mou-
vement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d’entretien et avant de faire démarrer le
moteur.
DESETINCELLESPEUVENTFAIREEX-
PLOSER UN ACCUMULATEUR;
L’ELECTROLYTE D’UN ACCUMU-
LATEUR PEUT BRULER LA PEAU ET
LES YEUX.
Les accumulateurs contiennent de l’électrolyte
acide et dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumu-
lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des
câbles d’accumulateur.
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
un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
LA VAPEUR ET LE LIQUIDE DE RE-
FROIDISSEMENT BRULANT SOUS
PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut
être brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
PRINCIPALES NORMES DE SECURITE
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-
ciation canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, norme ANSI Z87.1, American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
2-4 8-V-96
DESCRIPTION OF EQUIPMENT
General Description
The Model 2460 Heavy Duty CC/CV Wire Feeder
is designed to control the linear movement of 1/8
inch (3.2 mm) diameter (or less) tubular welding
electrode or 3/32 inch diameter (or less) solid weld-
ing electrode. The basic feeder has been designed
for self-shielding welding electrode and does not
have a gas solenoid.
For use of non self-shielding electrode, optional
gas solenoids are available and may be installed in
this portable feeder.
Metal Inert Gas (MIG) welding process joins metal
parts by electric arc which is established between a
filler metal (consumable welding wire) and the work.
The combination of the consumable wire with the
parent metal forms the weld.
This wire feeder may be used with either a con-
stant-voltage or constant-current type welding ma-
chine. A transformer-rectifier, motor-generator, or
engine-driven welding machine may be used.
Current Capacity and Rating
The welding current on this equipment is passed
through the feedhead assembly. Care must be
taken to make sure that the connections between
the feedhead and the power source connecting
cable as well as between the feedhead and gun
cable assembly connector are tight. Loose connec-
tions cause excessive heating and must be avoided.
This feeder uses arc voltage for its power. The
cable connection between the feedhead and the
power source also provide a power connection for
the feeder control. The other power connection is
made through the voltage sensing lead which must
be connected to the work terminal. Care must be
taken to make sure that the power cable connection
is made between the power source and work. If this
connection is not made, and an attempt is made to
strike an arc, serious damage to the feeder will
occur. By taking power from the welding arc, two
modes of operation result. These are termed CC
and CV mode. When a constant voltage power
source is used, the input voltage to the feeder
remains constant and a fixed wire feed speed will
result for a given dial selection on the feeder. If either
the power source voltage setting or the feeder set-
ting are changed, the output speed will change. This
is called CV mode of operation. When a constant
current power source is used, the arc voltage will
vary and as a result, the wire feed speed will vary
for a fixed dial setting on the feeder. This is called
CC mode of operation. When a constant current
power source is used, an increase in arc voltage will
cause an increase in wire feed speed, but an in-
crease in wire feed speed causes a decrease in arc
voltage. This results in a self-regulating system so
that the feeder keeps the arc voltage constant by
varying the wire feed speed as the arc attempts to
fluctuate. A switch on the back of the feeder is
provided to select between CV or CC. This switch
selects proper control stability for the mode being
used. The switch does not select the mode of
operation. The mode of operation is determined by
the type of power source being used.
The main application for this wire feeder is for CC
application using tubular self-shielding wires. Most
CC types of power sources do not have a remote
contactor control available. This means that the
electrode is always hot once the power source has
been turned on. It also means that the gun switch
on the wire feeder does not control the power
source, but only controls the starting and stopping
of the wire feeder itself. Since the power source
remains turned on, when the gun switch is released,
care must be taken when terminating the arc. When
the gun switch is released, the operator must also
pull the gun away fromthe arc to make sure that the
arc is extinguished and does not burn back into the
gun tip.
Internal limiting circuitry limits the maximumspeed
independent of input voltage. In addition, a slow
run-in circuit is provided which automatically re-
duces the run in wire feed speed when open circuit
voltage from a CC power source is present.
NOTE: Wire feeder input is protected by a
7 Amp slo-blow fuse. An 1/8 Amp fuse
protects the P.C. Board circuitry should a
short develop between the gun switch lead
to electrode lead. A 5 Amp slo-blow in-line
fuse inside the case protects the wire feed
motor.
Feedhead Assembly
The feed roll drive motor is solid-state controlled
on this unit. One of either of two different motors
(see Parts List for numbers of each) are used,
430429-249
DESCRIPTION OF EQUIPMENT
May 22, 1997 Revised 3-1
depending upon which wire feed rate is desired. See
Table 3-1 for correlation of numbers.
The assemblies consist of Feed Rolls (which are
made up of a Gear and Feed Roll) for various wire
types and/or sizes, Wire Input Guide, Output Guide,
Feedhead Mounting Plate, and Pressure Arm as-
sembly. The drive motor is 24 volts DC. See TIP-218
for details on the Feedhead Assembly. See Feed
Roll Kit drawing 375980 for selecting part numbers
for the Feed Rolls, Wire Guides, Contact Tubes, etc.
Tabulated Data
Gearmotor Permanent magnet
24 V DC, 1/8.8 HP
5A ± .5 amps
Speed:
123 RPM ± 12 RPM
57 RPM ± 5.7 RPM
(optional @ no
load)
Voltages
Motor 24 V DC
Gun Circuit 11 V DC or 24 V AC
(option)
Speed Range of Wire
20.4:1 drive gear ratio — 40 to 600 IPM
(inches/minute)
43.9:1 drive gear ratio — 20 to 300 IPM
(inches/minute) (optional)
Wire Data
Spool weight 60 pounds
(27.2 kg) max.
Sizes 1/8 inch (3.17 mm)
and smaller
Control Box Assembly
The Control Box contains control and connection
for the operation and component hook-up with the
particular welding system it is being used with. See
TIP-218 and MPL-224 included in this manual.
Wire Reel Support Assembly
The support bolts in place at the rear of the base-
plate. See I-169 included in this manual for details
on the installation and operation of the wire support
assembly.
Baseplate
See TIP-127 for details on the baseplate used for
this wire feeder when assembled to make the sub-
ject model configuration.
Options
The options available with this unit are as follows:
SPEC. MODEL
FEED
ROLLS
WIRE FEED
RATE
6877A-1 2460 4 40-600 IPM
6877B-1 2460 4 40-600 IPM
6877A-2 2460 4 20-300 IPM
6877B-2 2460 4 20-300 IPM
Table 3-1
430429-249
DESCRIPTION OF EQUIPMENT
3-2 May 22, 1997 Revised
ITEM DESCRIPTION
6877A-1
6877A-2
6877B-1
6877B-2
1
2
3
KIT, CONTACTOR WITH GV
KIT, CONTACTOR LESS GV
KIT, CONTACTOR WITH GV AND MEGA-ARC REMOTE CONTROL
376809-1
376809-2
376809-3
376809A-1
376809A-2
376809A-3
4
5
6
KIT, CONTACTOR LESS GV AND MEGA-ARC REMOTE CONTROL
KIT, CONTACTOR WITH GV AND MEGA-MIG REMOTE CONTROL
KIT, CONTACTOR LESS GV AND MEGA-MIG REMOTE CONTROL
376809-4
376809-5
376809-6
376809A-4
376809A-5
376809A-6
7
8
9
KIT, VOLT AND IPM METERS
KIT, MEGA-MIG, R.C. 15 FT.
KIT, MEGA-MIG, R.C. 25 FT.
376847
376810-1
376810-2
376847
376810-1
376810-2
10
11
12
KIT, MEGA-MIG, R.C. 50 FT.
KIT, MEGA-MIG, R.C. 75 FT.
KIT, MEGA-MIG, R.C. 100 FT.
376810-3
376810-4
376810-5
376810-3
376810-4
376810-5
13
14
15
KIT, MEGA-ARC, R.C. 25 FT.
KIT, MEGA-ARC, R.C. 50 FT.
KIT, MEGA-ARC, R.C. 75 FT.
376810-6
376810-7
376810-8
376810-6
376810-7
376810-8
16
17
18
KIT, MEGA-ARC, R.C. 100 FT.
CABLE CONTROL 6 FT.
CABLE, “Y” MEGA-ARC 6 FT.
376810-9
373059A
376510
376810-9
373059A
376510
19
20
21
CABLE, EXT 6 PIN 50 FT.
CABLE, EXT 6 PIN 100 FT.
CABLE, EXT 6 PIN 25 FT.
376511-1
376511-2
376511-3
376511-1
376511-2
376511-3
22
23
24
CABLE, EXT 6 PIN 75 FT.
CABLE, 19 PIN–10 PIN 10 FT.
CABLE, 10 PIN–LEAD 10 FT.
376511-4
376512-1
376513-1
376511-4
376512-1
376513-1
25
26
27
CABLE, 19 PIN–6 PIN 15 FT.
CABLE, 19 PIN–6 PIN 25 FT.
CABLE, 19 PIN–6 PIN 50 FT.
376514-1
376514-2
376514-3
376514-1
376514-2
376514-3
28
29
30
CABLE, 19 PIN–6 PIN 75 FT.
CABLE, 19 PIN–6 PIN 100 FT.
FRAME, SKID
376514-4
376514-5
493263
376514-4
376514-5
493263-1
31
32
33
KIT, HANDLE
KIT, CASTOR
EYE, LIFTING
375994
375605-2
375104
375994A
375605A-2
375104A
34
35
36
MOUNTING, SWIVEL
KIT, SPOOL
ADAPTER, SPOOL 10 LB.
375606-2
374831A
375585
375606A-2
374831A
375585-1
37
38
39
ADAPTER, SPOOL 15 LB.
ADAPTER, COIL 14 LB.
COVER, SPOOL 30 LB.
375584
375942
375582-2
375584-1
375942A
375582A-2
40
41
42
ADAPTER, COIL 60 LB.
KIT, REEL, WIRE
COVER, COIL 60 LB./SUPPORT/LIFTING EYE
407142
374819A
375733-1
407142A
374819A
375733A-1
NOTE: For installation and operation instructions for the above options, see the drawings and instructions
furnished with each kit. The Welding Gun and Cable Assembly used with the Feedhead in the manual is
covered by an Owner’s Manual. (See TIP publication included in this manual for particular Feedhead
used.)
430429-249
DESCRIPTION OF EQUIPMENT
May 22, 1997 Revised 3-3
This page intentionally left blank.
430429-249
DESCRIPTION OF EQUIPMENT
3-4 May 22, 1997 Revised
OPERATION
Prewelding Checks
Before attempting to operate the Model 2460
Heavy Duty CC/CV Wire Feeder, make certain that
all installation instructions, including those for the
welding machine (power source), and the welding
gun and cable, have been carried out.
1. With the feeder properly connected to the power
source and the work cables properly connected
from power source to work and from feeder to work,
turn on the power source.
WARNING: When the power
source is turned on, the elec-
trode (welding wire) is electri-
cally “hot”. Do not permit it to
touch any metal or a welding arc
may be established which may
be injurious to someone’s eyes
(flash) or skin (burn).
2. Select CC/CV characteristic on motor control
circuit and set switch accordingly.
3. Determine desired operating voltage in case of
a CV power source or desired operating current in
case of a CC power source and set power source
accordingly.
4. Set control on feeder to an approximate 3
position on the dial.
NOTE: When using a CV power source,
increasing dial position will increase wire
feed speed and as a result increase weld-
ing current.
When using a CCpower source, increasing
dial position will increase wire feed speed
and as a result will decrease arc voltage.
Welding
1. Position the gun above the workpiece but do not
touch the electrode to the work as this will cause arc
flash. With the gun in the proper position and eyes
fully protected, pull the gun switch which will cause
an arc to be initiated.
2. Releasing the gun switch trigger will cause the
wire to stop feeding. At this time the gun must be
pulled away from the work in order to extinguish the
arc.
3. When the welding has been completed, or at the
end of the work day, it is recommended that the
power source and feeder be turned off.
430429-249
OPERATION
May 22, 1997 Revised 4-1
This page intentionally left blank.
430429-249
OPERATION
4-2 May 22, 1997 Revised
PARTS LIST
Equipment Identification
All identification numbers as described in the In-
troduction chapter must be furnished when ordering
parts or making inquiries. This information is usually
found on the nameplate attached to the equipment.
Be sure to include any dash numbers following the
Specification or Assembly numbers.
How To Use This Parts List
The Parts List is a combination of an illustration
(Figure Number) and a corresponding list of parts
which contains a breakdown of the equipment into
assemblies, subassemblies, and detail parts. All
parts of the equipment are listed except for commer-
cially available hardware, bulk items such as wire,
cable, sleeving, tubing, etc., and permanently at-
tached items which are soldered, riveted, or welded
to another part. The part descriptions may be
indented to show part relationships.
To determine the part number, description, quan-
tity, or application of an item, simply locate the item
in question from the illustration and refer to that
item number in the corresponding Parts List.
An “Application Code” is used to distinguish parts
that are applicable only to certain Specifications
and/or Assemblies. This code is found in the right-
most column of the Parts List. If an iteminthe Parts
List applies to all Specifications or Assemblies, the
word “ALL” will be in the Application Code column.
Refer to the following list to determine the appro-
priate Application Codes for the Specifications or
Assemblies covered by this manual. If only the
assembly or specification number is listed, the use
of an Application Code does not apply to this
manual.
SPECIFICATION NUMBER APPLICATION CODE
6877A-1 A
6877A-2 B
6877B-1 C
6877B-2 D
430429-249
Troy, Ohio 45373 PARTS LIST
November 2, 1999 Revised 5-1
Figure 5-1 Wire Feeder Assembly
430429-249
PARTS LIST Troy, Ohio 45373
5-2 June 18, 1999 Revised
S-6877A-1 Wire Feeder, CC/CV Operation
4-Roll Drive, 40-600 IPM 1 A
S-6877A-2 Wire Feeder, CC/CV Operation
4-Roll Drive, 20-300 IPM 1 B
S-6877B-1 Wire Feeder, CC/CV Operation
4-Roll Drive, 40-600 IPM 1 C
S-6877B-2 Wire Feeder, CC/CV Operation
4-Roll Drive, 20-300 IPM 1 D
1 376783B . Box - Control Assembly
(For Details See Figure 5-2) 1 AB
376783B-1 . Box - Control Assembly
(For Details See Figure 5-2) 1 CD
2 376799A-1 . Feedhead - Assembly 40-600 IPM
(For Details See MPL-224) 1 A
376799A-3 . Feedhead - Assembly 40-600 IPM
(For Details See MPL-224) 1 C
376799A-2 . Feedhead - Assembly 20-300 IPM
(For Details See MPL-224) 1 B
376799A-4 . Feedhead - Assembly 20-300 IPM
(For Details See MPL-224) 1 D
3 375769-1 . Base 1 AB
375769-4 . Base 1 CD
4 374818A-1 . Support - Wire Spool Assembly
(For Details See I-169) 1 AB
374818A-9 . Support - Wire Spool Assembly
(For Details See I-169) 1 CD
— 376827 List - Field Installable Options Ref. All
5 870087-1 Label - Thermal Arc 2 All
6 870194-1 Cable - Assy 1 All
— Not Illustrated
Item Part Description Qty Application
No Number per Code
Assy
Parts List for Figure 5-1
430429-249
Troy, Ohio 45373 PARTS LIST
November 2, 1999 Revised 5-3
Figure 5-2 Control Box Assembly
430429-249
PARTS LIST Troy, Ohio 45373
5-4 June 18, 1999 Revised
376826 Cover - Control Box Assembly 1 AB
376826-1 Cover - Control Box Assembly 1 CD
1 376782-1 . Cover - Control Box 1 AB
376782-2 . Cover - Control Box 1 CD
2 Deleted
3 204036 . Label - Precautionary 1 All
376783B Box - Control Assembly 1 AB
376783B-1 Box - Control Assembly 1 CD
4 405535-2 . Support - P.C. Board 4 All
5 376807C . Board - P.C., Motor Control 1 All
6 401937-2 . Block - Terminal, 20 Amp, 8 Station 1 All
7 407146 . Label - Terminal Block 1 All
8 403704-1 . Switch - Rocker, ON/OFF 1 All
9 Deleted
10 406926-3 . Potentiometer - 10K, 2 W 1 All
11 40209 . Strip - Weather, 1/16 x 1/2 68-1/4" All
12 40207 . Strip - Weather, 1/16 x 1/4 15-3/4" All
13 376718 . Plate - Cover 2 AB
376718-1 . Plate - Cover 2 CD
14 Deleted
15 406806 . Knob - Control 1 AB
406806-3 . Knob - Control 1 CD
16 408246-1 . Clip - Nylon 7 All
17 403091-4 . Plug - Hole, Plastic 1 All
18 402037-3 . Grommet 1 All
19 . Deleted
20 403091-2 . Plug - Hole, Plastic 2 All
21 405576-1 . Bushing - Terminal 1 All
22 376711B-1 . Wrapper - Control Box 1 AB
376711B-2 . Wrapper - Control Box 1 CD
23 W-10051-2 . Clamp - Wire Plastic 1 All
24 409838 . Grommet - Mtg. 4 All
25 409837 . Spacer - Nylon 4 All
26 371635 . Adapter - Gas R.H. 1 All
27 408242-1 . Fuseholder 2 All
2 28 401972-5 . Fuse - Slo-Blow, 7 Amp 1 All
— Not Illustrated
Item Part Description Qty Application
No Number per Code
Assy
Parts List for Figure 5-2
430429-249
Troy, Ohio 45373 PARTS LIST
November 2, 1999 Revised 5-5
29 407097-1 . Switch - Toggle 1 All
— 403031 . Seal - Switch 1 All
— 408243-1 . Boot - Switch 1 All
30 401972-2 . Fuse - 5 Amp, Slow Blow 1 All
— 406008-13 . Receptacle, 6 Position 1 All
— 406008-3 . Receptacle, 12 Position 1 All
— 406008-10 . Receptacle, 4 Position 1 All
— 406009-1 . Plug - Keying 3 All
31 404065-2 . Rectifier - Bridge 1 All
32 407961A-1 . Nameplate - Prod. Info. 1 All
33 170656 . Label - Fuse 1 AB
34 405535-5 . Support - P.C. Board 4 All
35 376507 . Board - P.C. Gas Valve 1 All
36 403091-11 . Plug - Hole, Plastic 1 All
— Not Illustrated
Item Part Description Qty Application
No Number per Code
Assy
Parts List for Figure 5-2
430429-249
PARTS LIST Troy, Ohio 45373
5-6 June 18, 1999 Revised
CONTROL BOX ASSEMBLY NO. 376783A & 376783B
DESCRIPTION, INSTALLATION, OPERATION AND MAINTENANCE
Description
The Control Box assembly is the control medium
for the operation of the Feedhead. Wire FeedSpeed
rate (IPM Inches-per-minute) is selected and regu-
lated by the knob (potentiometer) on the front panel.
The box is designed to function as a component of
the 2000 Series Wire Feeder composite assembly,
or as remote-mounted control medium, not situated
close to the Feedhead. A side panel is available to
replace the Feedhead Mounting Plate (see Figure
1) when used in a remote situation.
Controls and Connections
A. CV operation. When using a CV power source,
this control is used to control wire feed speed. To
increase wire feed speed, turn the control knob
clockwise. To decrease wire feed speed, turn the
knob counterclockwise.
B. CC operation. When using a CC power source,
this control is used to control arc voltage by varying
wire feed speed. To increase arc voltage (decrease
wfs), turn knob counterclockwise. To decrease arc
voltage (increase wfs), turn knob clockwise.
NOTE: Many CC power sources have a
drooping V-I characteristic. On these
types of power sources, the current is not
exactly constant and changing the arc
voltage will also change the output cur-
rent. This again becomes a self-regulat-
ing stable system.
ON-OFFRocker Switch —This switchcontrols the
input circuit, applying or removing the input voltage
of the unit.
Gun Switch Receptacle — The gun switch control
cable connects to the gun switch receptacle (quick-
disconnect type) to provide control from the gun
switch to the wire feed mechanism.
Welding Gun Cable Connector — The gun cable
is connected to the wire feeder at this receptacle.
Connections must always be tight.
Fuse 7 A — The unit is equipped with a 7 A MDX
slow blow fuse. This fuse is rated at 125 volt and
may never be replaced with a fuse of lower voltage
rating as this could cause serious damage to the
equipment.
Fuse 1/8 A — Protects P.C. Board from welding
electrode shorting to gun switch circuit.
Figure 1 Controls - Connections (Front End)
TIP-218
CONTROL BOX ASSEMBLY NO. 376783A & 376783B
May 29, 1996 Revised Page 1
Fuse 5 A — Protects motor from excessive stall
current.
Label — Identifies 5 A fuse rating and location
(inside control box).
CC/CV Switch — This is a two-position switch that
controls the droop characteristics of the motor con-
trol circuit. When in the CV position, the circuit uses
IR compensation giving an almost flat speed torque
curve. When in the CC position, the IR compensa-
tion is eliminated and the speed torque curve has a
fairly high droop. The CV position is recommended
for all CV types of power sources. The CC position
is generally recommended when using a CC power
source. For many types of wires however, the CV
position is recommended even when a CC power
source is used.
A 12-volt gas valve and P.C. Board control the
shielding gas for solid wire welding. Welding gas will
flow when the gun switch is closed.
The circuit board uses the output voltage of the
bridge rectifier CR1 and converts this output into a
12-V DC voltage. The gas valve is a part of the total
DC to DC converter circuit and is always connected
in the circuit.
The circuit board is installed next to the motor
control board.
Installation
Location
The model 2460 heavy duty CC/CV wire feeder is
designed to withstand high moisture conditions en-
countered in outdoor welding applications. How-
ever, the wire feeder is not waterproof and therefore
should not be stored outdoors for extended periods
of time.
Connections
1. Make sure that the proper welding cable con-
nections exist between the feeder feedhead (elec-
trode) to power source and work connection to
power source. Connect Feeder work lead (Figure 1)
to work.
Figure 2 Connections (Rear End of Enclosure)
TIP-218
CONTROL BOX ASSEMBLY NO. 376783A & 376783B
Page 2 May 29, 1996 Revised
2. Attach the gun and cable to the wire feeder by
following instructions found in the Owner’s Manual
for the Gun and Cable assembly.
WARNING: The welding elec-
trode is electrically “Hot”. Elec-
trode contact to workpiece will
cause an arc withthe wire feeder
connected to the workpiece and
gun switch depressed — feed
motor will run feeding “HOT”
electrode.
Operation
Theory of Operation
Refer to Connection Diagram 376784A
With the wire feeder connected to the welding
electrode and the work terminal, turn the power
source and wire feeder on. Power is supplied into
Bridge rectifier CR1. Power on the output side of the
CR1 is fed to the motor control board with the proper
polarity independent of the welding polarity.
When the welding gun switch (S4) is closed, it
energizes the proper components on the PC Board
and causes the motor to run. When the gun switch
is opened, it removes power from the motor and
shorts the armature to provide dynamic braking of
the motor.
When the CC/CV switch (S5) is open, IR compen-
sation is used on the motor control circuit. When S5
is closed, the IR compensation circuit is not active.
Terminal strip TB1 is used to connect various
options to the feeder.
Switch S1 is used to turn the power into the feeder
on or off.
Resistor R1 is the control potentiometer for the unit
which varies the output speed.
The motor control circuit on this feeder is a DC to
DCconverter circuit. It uses the power supply output
voltage and changes it to the proper DC voltage
required to operate the motor. The motor is part of
the operating circuit, and the circuit will not operate
properly if the motor is removed.
The circuit is designed for continuous operation
when the input voltage is 30 volts or below. Many
CC power sources have an open circuit voltage of
60 to 100 volts. Under these input conditions, the
circuit will operate and the motor will run. This
condition may exist for a period long enough to feed
wire through the gun when wire spools arechanged,
etc., but the motor must never be allowed to operate
with open circuit voltage for prolonged periods of
time.
Options
1. Remote Contactor Control Option —This option
is externally located and connects to the feeder by
means of a control cable which is added to the
feeder. When this option is installed, a relay is
added to the feeder and a 24-V ACgas valve option
is available.
The remote box requires 115-V AC input and in
turn provides 24 V AC to the feeder as well as a
contactor control relay closure to the power source.
The 24 V AC is also used to allow for inching of the
wire feed motor.
2. A voltmeter kit as well as an inches per minute
kit are available for this unit.
3. A remote arc voltage/current control is also
available which allows the user to adjust the power
source at the feeder.
Maintenance
Cleaning of the Unit
Periodically remove a side panel of the cabinet,
and blow out the interior with clean, dry, com-
pressed air of not more than 25 psi (172 kPa)
pressure. Do not strike any of the components with
the air hose nozzle.
TIP-218
CONTROL BOX ASSEMBLY NO. 376783A & 376783B
May 29, 1996 Revised Page 3
Troubleshooting
The following chart contains information which can be used to diagnose and correct unsatisfactory operation
or failure of various components of the unit. Each symptom of trouble is followed by a list of probable causes
and procedures to correct them.
Wire does not feed, open-circuit voltage is normal
Switch on Feeder not on or bad
Check and correct.
Fuse open on Feeder
Check and replace.
Work lead not connected
Check and connect.
Cables from Power Sources not properly connected
Check and connect.
Gun switch defective
Check for proper operation.
Feed rolls not properly tightened
Correct situation.
Bad PC board on feeder
Replace.
5 A internal fuse blown
Replace fuse.
Erratic weld output
Ground clamp loose at WORK connection
Check ground clamp for secure attachment.
Gun liner dirty
Check gun liner and replace if necessary.
Voltage/current and feeder settings are not correct
Readjust as necessary.
Improper wire for gas less welding
Change to proper wire.
Wire feed motor operates, but wire does not feed
Too little pressure on wire feed roll
Increase pressure adjustment.
Incorrect wire groove
Check wire size stamped on outside of feed roll. Match to wire size.
TIP-218
CONTROL BOX ASSEMBLY NO. 376783A & 376783B
Page 4 May 29, 1996 Revised
Wire spool tension too great
Loosen adjusting screw.
Restriction in gun or cable assembly
Examine cable, gun, and current contact tube (tip) for damage and correct size.
Make sure correct contact tube and liner is being used.
Welding current or voltage not stable
Wire slipping in rolls
Readjust pressure on the drive roll pressure arm.
Restriction in gun cable or gun
See Welding Gun and Cable Description and Maintenance.
Wrong size liner or contact tube
Match liner and contact tube to electrode wire size.
Incorrect voltage adjustment for selected wire speed on the welding machine
Readjust. See Welding Guide in Operation section.
Loose connection on the welding leads or work table
Check and tighten all connections.
Wire wraps around the drive roll
Too much feed roll pressure
Decrease the pressure adjustment on the drive roll pressure arm.
Incorrect liner or contact tube
Make sure that liner and/or contact tube is correct for the size of wire being fed.
No speed control
Broken or loose wires in wire feed control circuit
Correct by checking all connections.
Bad PC board
Replace.
Bad wire feed speed control potentiometer
Replace.
No gas flow
Gas valve not energizing
Broken lead to valve.
Bad PC board
Replace.
Open gas valve coil
Replace gas valve.
TIP-218
CONTROL BOX ASSEMBLY NO. 376783A & 376783B
May 29, 1996 Revised Page 5
This page intentionally left blank.
TIP-218
CONTROL BOX ASSEMBLY NO. 376783A & 376783B
Page 6 May 29, 1996 Revised
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4
DESCRIPTION, INSTALLATION, OPERATION AND MAINTENANCE
Description
The four-roll feedhead assembly consists of four
idler gear/feed rolls (item 2, Figure 1) for various
types and sizes of wire. See Feed Roll Kit (375980),
wire input guide (item 1), center guide (item 7),
output guide (item 5), feedhead plate (item 4) and
pressure arm assembly (item 6). The drive motor is
115 volt DC, controlled by solid-state or variac
speed control. See the data on the particular model
which is found in the manual of which this TIP is a
part.
Wire sizes from 0.030-inch (0.76 mm) diameter to
1/8 inch (3.18 mm) may be fed with selection of
proper feed rolls. See Feed Roll Kit (Drawing
375980-X, included in this manual) for feed roll
configuration and proper feed rolls for given sizes
and types of wire.
The Solenoid (Gas Control) Valve (optional) is
located on the back side of the Feedhead Plate. A
fitting for gas supply extends through the back panel
of the Control Box.
Installation
The feedhead assembly becomes a part of the
modular assembly which includes a control box
assembly, and a wire support assembly which may
be mounted on a common baseplate, or remotely
mounted, as on a boom unit.
Location — For best operating characteristics and
longest unit life, take care in selecting an installation
site. Avoid locations exposed to dust, high ambient
temperature, or corrosive fumes.
Connections — The electrical connections for the
wire feeder are made both at the feedhead and
control box. The feedhead connection is made from
the power supply terminal to the feedhead as with
standard feeders. However, the feeder motor and
controls use the feedhead potential to supply oper-
ating power for the feeder. Be sure the cable con-
nection to the feedhead is tight. A loose cable will
cause the feeder to malfunction.
Installation of Welding Wire Spool —See I-169 for
details.
Adjustment of Spool Tension —Adjust the tension
on the Wire Spool so that the wire will feed freely
into the feedhead (feed rolls), but will not “coast”
when wire feeding stops. Tighten or loosen the Hub
Tension Screw accordingly.
Threading Wire Into Feedhead — Refer to Figure
2.
CAUTION: Use care when handling the
spooled wire as it tends to unravel when
loosened from the spool. Grasp the end
of the wire firmly; do not let it get away!
Make sure the end of the wire is free of
burrs, and that it is straight.
1. Loosen the Pressure Arm Knobs, and raise the
Pressure Arm UP as shown in Figure 2.
2. Place the end of the wire into the Input Guide,
feeding it through the guide and over the feed roll
grooves.
3. Pass the wire into the Output Guide and on into
the Gun Cable. See Owner’s Manual for the Gun
and Cable Assembly.
4. Make sure that the wire is directly over the
grooves in the feed rolls and replace the Pressure
Arm. Lock it in place with the Pressure Arm Knobs.
Figure 1
1. Input Guide
2. Idler Gear/Feed Roll
3. Drive Gear
4. Feedhead Plate
5. Output Guide
6. Pressure Arm
Assembly
7. Center Guide
TIP-219
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4
December 1, 1997 Revised Page 1
Installing Gun and Cable Assembly — Refer to
Figure 3. The Feedhead is designed for use with
TWECO Guns and Cables. To install one of these
guns, loosen the Gun Receptacle Knob and insert
the gun Quick Connect Receptacle into the Feed-
head until it bottoms out against the Output Guide.
Tighten Gun Receptacle Knob. See “A” and “B”
assemblies on Figure 3.
If a TWECO #5 Backend Gun and Cable is to be
installed, the Gun Sleeve must be removed, the Gas
Inlet must be removed and replaced with another
one. See “B” on Figure 3. The Gas Inlet comes in a
kit (375999). To install the Gun and Cable, proceed
as follows:
1. Remove the Gun Receptacle Knob.
2. Remove the two retaining screws which secure
the Gas Inlet into the Feedhead Plate. This allows
the Gas Inlet to pull straight out.
3. Hold the Gas Tube (with hose attached) and
turn the Gas Inlet counterclockwise to unscrew and
remove it. Screw the Gas Tube into the Gas Inlet
provided in kit 375999, but do not yet install the Gas
Inlet into the Feedhead.
4. Hold the Gun Receptacle and remove the Gun
Sleeve (used only on the TWECO #4 Backend
Guns). Lower the Gun Receptacle.
NOTE: If the Gun Sleeve does not come
out easily, insert a screwdriver into the
slot (see Figure 3) and gently, but firmly,
pry the sleeve out.
5. Slide the new Gas Inlet (with Gas Tube in-
stalled) into place, making sure that the wide
groove, toward feed rolls, goes in first.
6. Replace the Retaining Screws to secure the
Gas Inlet into place.
NOTE: When the TWECO #5 Backend
Gun and Cable is installed, it may be nec-
essary to change the Output Guide, de-
pending upon new wire size. See
instructions for changing Output Guide in
Installing Feed Rolls and Guides.
7. Raise the Gun Receptacle and reinstall the Gun
Receptacle Knob. Do not tighten at this time.
8. Insert the quick-connect receptacle on the Gun
Cable into the Feedhead, and tighten the Gun Re-
ceptacle Knob to a “snug” position. See Gun and
Cable Manual for details on these parts.
9. Attach electrode lead to the Gun Receptacle by
use of a bolt in the threaded hole at the lower end
of the receptacle.
Figure 2
TIP-219
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4
Page 2 December 1, 1997 Revised
Installing Feed Rolls and Guides — Feed Rolls,
Input Guides, and Output Guides are supplied in
Feed Roll Kit 375980-X, depending upon wire size,
type, and Feed Roll style. Follow the procedure
below for initial installation or changing Feed Rolls
and/or guides for different wire size or type. See
Figure 2 for reference to components below.
NOTE: When Feedhead assembly is
shipped from factory, the Feed Roll
Screws (quantity of 12) are placed sepa-
rately in a cloth bag and furnished with
the Feedhead assembly.
Feed Rolls
1. Locate and open the cloth bag with twelve
feedhead screws (#8-32 x 1" allen socket-head
screws).
2. Select proper Feed Rolls and Guides. See
375980 and determine the proper dash (–) number
for wire type, Feed Roll style, Feed Roll part num-
bers, Input Guide, Center Guide, and Output Guide
part numbers.
3. Loosen the Pressure Arm Knobs and lift the
Pressure Arm off.
4. Install Center Guide in place before installing
both bottom Feed Rolls. See Figure 2.
NOTE: The Center Guide may be in-
stalled if only one, but not both lower
Feed Rolls are in place.
5. Install the two lower Feed Rolls onto the Idler
Gears. See Figure 4. Insert three Feed Roll screws
in each roll and tighten.
Figure 3
Figure 4
TIP-219
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4
December 1, 1997 Revised Page 3
NOTE: An Allen wrench is supplied for
tightening the Feed Roll Screws. It is
“stored” in a nylon retainer, located on
the rear end of the Feedhead Cover. See
Figure 6.
6. To install the upper two Feed Rolls, follow the
procedure below:
a. Remove shaft screws which secure the
Idler Gear/Shaft in place in the pressure arm.
See Figure 5.
b. Install the Feed Rolls onto the Idler Gears,
and secure in place with the Feed Roll
Screws. See Figure 4.
NOTE: When installing a Style 4 Feed
Roll, which is made up of two pieces, be
sure to place the narrow piece on the
gear first. This makes the groove line up
with the Guides.
c. Reinstall the Idler Gears/Feed Rolls into
the Pressure Arm. Fasten in place with the
Shaft Screws. See Figure 5.
d. Reassemble Pressure Arm onto the Feed-
head Assembly by dropping it into place (see
Figure 2) and adjusting the Pressure Arm
Knobs for proper tension. Adjust Center
Guide so that clearance between Guide and
the first Feed Roll is approximately 1/32 inch
(0.8 mm). Tighten Center Guide Retaining
Screw.
Input Guides
1. Loosen the Input Guide Retaining Screw and
pull the Input Guide Spring (Item 1, Figure 1) out of
the hex nylon Input Guide.
2. Insert the steel or nylatron Input Guide into the
hex nylon Input Guide.
NOTE: The hex nylon Input Guide is a
holding device for the Input Guide Spring
and the Input Guide which is supplied in
the Feed Roll and Guides Kit (375980-*).
*The dash number denotes which Feed
Rolls and Guides are furnished.
3. Reinstall the Input Guide Spring, pushing it
against the Input Guide, and tighten the Retaining
Screw.
Output Guide — The Output Guide may be in-
stalled with the Gun Sleeve and the Gas Inlet (all
models) in place.
1. Loosen the Output Guide Retaining Screw (see
Figure 2), and turn it out far enough to allow the
Guide to slide in or out.
2. Insert the Guide into the Feedhead with long-
nosed pliers or a piece of welding wire. Push the
Guide up to the Feed Rolls until it “bottoms out”
inside the Feedhead and tighten the Retaining
Screw.
3. Proceed to install the Gun and Cable Assembly
as detailed above under Installing Gun and Cable
Assembly.
Operation
The operation of this feedhead is a function of the
wire feeder assembly of which it becomes a part.
See the Wire Feeder Manual for the 2000 Series for
details which affect this operation.
Maintenance
Cleaning — Periodically blow off the feedhead
assembly with clean, dry, compressed air of not
more than 25 psi (172 kPa) pressure. Use care to
not strike component parts of the feedhead with the
air hose nozzle.
Cleaning Feed Rolls and Gears — Using a small
wire brush, clean the grooves on the feed rolls and
gear teeth frequently. To clean the wire groove,
loosen the Pressure Arm Knob and raise the Pres-
sure Arm. Remove the wire from the feed rolls.
Clean the gear teeth and check the screws which
hold the feed rolls on the gears.
Feedhead Maintenance —The only point of main-
tenance in the feedhead assembly is the motor
brushes. To inspect and/or change the brushes, the
feedhead assembly must be removed fromthe Con-
Figure 5
TIP-219
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4
Page 4 December 1, 1997 Revised
trol Box (in the 2000 Series composite assembly).
See Figure 6 and instructions for removing feed-
head and motor from Control Box.
NOTE: There are two possibilities for
wire feed motors, depending upon which
manufacturer’s stock was used for the
particular assembly. The removal from
the Control Box is the same for both mo-
tors, but the procedure for changing
brushes is different.
1. Remove six screws from the top and side of the
Control Box which holds the Control Box Cover in
place. Loosen the screws (2) at the bottom of the
Cover, to allow the Cover to slip up off from the
screws in the slots provided.
2. Disconnect the power supply wire from the gun
receptacle. Remove the four screws and lockwash-
ers which secure the Feedhead Mounting Plate to
the side of the Control Box. This will allow the
Feedhead assembly (including the motor) to pull
straight out of the Control Box, to a position (see
Figure 6) where the motor brushes may be serviced.
3. The Bodine gear motors are equipped with a
vent for the gearbox. The vent hole is plugged and
does not have to be removed for operation.
Bodine Motor Brush Inspection and Installation —
See Figure 7 — The brushes should be inspected
every 300 hours of operation. When brushes are
worn to about 3/8 inch (9.5 mm) in length, new
brushes should be installed. (Refer to Parts List for
brush part numbers.) See Figure 7 for following
procedure.
CAUTION: Neglect in brush mainte-
nance may cause damage to commuta-
tor in the motor if allowed to wear away
completely.
1. See Step 1 on Figure 7. Lift and remove the
Brush Cap by prying the Rivet out of the hole in the
End Shield. This will reveal the brush assembly in
place as in Step 2.
2. Using long-nosed pliers, grasp the Spring Re-
taining Bracket. Slightly push the Retaining Spring
down and toward the brush. When the Bracket
unhooks fromthe Brush Box, lift the Retainer/Spring
out.
3. Using long-nosed pliers, grasp the connector on
one end of the brush pigtail and pull it straight up.
Disconnect it from the clip on the side of the Brush
Box. The Brush may be removed at this time.
Figure 6
TIP-219
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4
December 1, 1997 Revised Page 5
NOTE: Blow dirt and foreign matter out of
the Brush Box with compressed air of not
more than 25 psi (172 kPa) pressure.
4. Install new brushes if necessary. Reassemble
the unit in reverse order of the dismantling proce-
dure.
Stature Motor Brush Inspection and Installation —
See Figure 8.
1. Remove Brush Cap from the End Cap using a
screwdriver. As the cap is removed, the spring on
the Brush Pigtail will pop up out of the hole.
NOTE: Observe the direction which the
spring bends in order to reinstall the
brush in the same position, for best fit to
the motor commutator.
2. Lift the Brush/Spring out of the Brush Box.
3. Inspect Brush, check dimensions, blow out the
Brush Box with compressed air (see NOTE above).
4. Install new Brush/Spring, if necessary, and
screw the Brush Cap into the threaded hole.
5. Install the feedhead assembly into the Control
Box in reverse order to that in Feedhead Mainte-
nance, paragraph 1 and 2, above.
Figure 8
Figure 7
TIP-219
FEEDHEAD ASSEMBLY NO. 376799A-1, -2, -3, -4
Page 6 December 1, 1997 Revised
PARTS LIST FOR ASSEMBLY NUMBERS 376799A-1,-2, -3, -4
Equipment Identification
All identification numbers as described in the In-
troduction chapter must be furnished when ordering
parts or making inquiries. This information is usually
found on the nameplate attached to the equipment.
Be sure to include any dash numbers following the
Specification or Assembly numbers.
How To Use This Parts List
The Parts List is a combination of an illustration
(Figure Number) and a corresponding list of parts
which contains a breakdown of the equipment into
assemblies, subassemblies, and detail parts. All
parts of the equipment are listed except for commer-
cially available hardware, bulk items such as wire,
cable, sleeving, tubing, etc., and permanently at-
tached items which are soldered, riveted, or welded
to another part. The part descriptions may be in-
dented to show part relationships.
To determine the part number, description, quan-
tity, or application of an item, simply locate the item
in question fromthe illustration and refer to that item
number in the corresponding Parts List.
An “Application Code” is used to distinguish parts
that are applicable only to certain Specifications
and/or Assemblies. This code is found in the right-
most column of the Parts List. If an itemin the Parts
List applies to all Specifications or Assemblies, the
word “ALL” will be in the Application Code column.
Refer to the following list to determine the appropri-
ate Application Codes for the Specifications or As-
semblies covered by this manual. If only the
assembly or specification number is listed, the use
of an Application Code does not apply to this man-
ual.
ASSEMBLY NUMBER APPLICATION CODE
376799A-1 A
376799A-2 B
376799A-3 C
376799A-4 D
MPL-224
PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4
May 29, 1996 Revised Page 1
Figure 1 Feedhead Assembly
MPL-224
PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4
Page 2 May 29, 1996 Revised
376799A-1 Feedhead - 4 Roll, 600 IN./MIN.
Heavy Duty, CC/CV Assy 1 A
376799A-2 Feedhead - 4 Roll, 300 IN./MIN.
Heavy Duty, CC/CV Assy 1 B
376799A-3 Feedhead - 4 Roll, 600 IN./MIN.
Heavy Duty, CC/CV Assy 1 C
376799A-4 Feedhead - 4 Roll, 300 IN./MIN.
Heavy Duty, CC/CV Assy 1 D
1 406846 . Arm - Pressure 1 All
2 376001A . Knob - Pressure Arm 2 All
3 400562-38 . Spring - Compression 2 All
4 375784A . Washer - Pressure Arm 2 All
5 375789 . Rod - Pressure Arm 2 All
6 16DA-1202-13 . Pin - Spring 2 All
7 5CW-3884-2 . Screw - #10-24 x 1/2, HH, MH, ST. 1 All
8 406397 . Guide - Input 1 All
9 376037 . Spring - Input Guide Assy 1 All
10 16DA-1202-11 . Pin - Spring 1 All
11 375920 . Plate - Feedhead, 4 Roll 1 All
12 No Number . Screw - #10-32 x 1/2, Rd. Hd. MH. ST. 2 All
13 No Number . Screw - 1/4-20 x 3/4, Rd. Hd. MH. ST. 1 All
14 No Number . Washer - LK. Std., 1/4 10 All
15 No Number . Washer - FL. ST. 1/4 6 All
16 375793 . Washer - Insulating 2 All
17 406985 . Gear - Feed Roll, Assembly 1 All
18 375836 . Spacer - Feedhead 1 All
19 405836-3 . Ring - Snap, Retaining 1 All
20 407075-1 . Shim - .005 Thickness 3 All
21 407075-2 . Shim - .015 Thickness 3 All
22 406639-2 . Ring - Snap, External 1 All
23 407133-1 . Knob - Gun Receptacle 1 All
24 375787 . Spacer - Gun Receptacle 1 All
25 407044 . Screw - Retaining 2 All
26 375781-2 . Receptacle - Gun 1 All
27 No Number . Screw - 3/8-16 x 3/4 HHC, ST. 1 All
28 No Number . Washer - LK, ST. 3/8 1 All
29 No Number . Washer - FL, ST. 3/8 1 All
30 375962 . Sleeve - Gun 1 All
Item Part Description Qty Application
No Number per Code
Assy
Parts List for Figure 1
MPL-224
PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4
May 29, 1996 Revised Page 3
31 375981 . Inlet - Gas 1 All
32 375298 . Tube - Gas 1 All
33 375840 . Spacer - Feedhead 3 All
34 375792 . Spacer - Feedhead 3 All
35 16DA-1202-3 . Pin - Spring 1 All
36 No Number . Screw - 1/4-20 x 1-1/4, HHC, ST. 1 All
37 402119-10 . Screw - 1/4-20 x 2, HHC, ST. 2 All
38 16DA-4249-5 . Ring - Snap, External 4 All
39 407108 . Washer - Flat 4 All
40 375921 . Gear - Feed Roll, Assembly 4 All
41 W-11144-3 . Screw - #8-32 x 1, Cap Socket Hd. 12 All
42 375790 . Shaft - Feed Roll 2 All
43 375825 . Spacer - Feedhead, Locating 1 All
44 403091-13 . Plug - Hole, Plastic 2 All
45 407567 . Label - Instruction 1 All
46 376804-1 . Strip - Weather 1 All
47 402037-25 . Grommet 1 All
48 No Number . Screw - #8-32 x 3/8 HWH, SF-Tap 1 All
49 No Number . Washer - #8, LK 1 All
50 404162-5 . Valve - Solenoid, 12 V 1 All
51 402927-1 . Connector - Male 1 All
52 No Number . Tie - Cable 1 All
53 16DA-3304-22 . Tubing - Gas, Water 1 All
54 370495A . Connector - Gas Hose 1 All
55 No Number . Clamp - Hose 1 All
56 373130-10 . Hose - Rubber 1 All
376130-11 . Cover - Mtg. Feedhead Assy 1 AB
373130-17 . Hose - Rubber 1 CD
57 375764-1 . . Cover - Feedhead Assembly 1 AB
375764-4 . . Cover - Feedhead Assembly 1 CD
58 407152-1 . . Rivet - Blind, Plastic 1 All
59 406334-4 . . Wrench - Allen 1 All
60 407175-1 . . Spring - Retaining, Door 1 All
61 376716-1 . . Plate - Mtg. Feedhead 1 AB
376716-2 . . Plate - Mtg. Feedhead 1 CD
62 407138 . . Label - Tension Indicator 2 All
63 407099 . . Label - Electric Shock 1 All
Item Part Description Qty Application
No Number per Code
Assy
Parts List for Figure 1
MPL-224
PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4
Page 4 May 29, 1996 Revised
64 406636 . . Label 1 All
65 376721-1 . Motor - Gear, Feedhead Assy 1 A
376721-2 . Motor - Gear, Feedhead Assy 1 B
66 407192 Spring - Brush 2
67 407086 Cap - Brush 2
68 407193 Rivet 2
69 407089 Brush 2
Item Part Description Qty Application
No Number per Code
Assy
Parts List for Figure 1
MPL-224
PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4
May 29, 1996 Revised Page 5
This page intentionally left blank.
MPL-224
PARTS LIST FOR ASSEMBLY NUMBER 376799A-1, -2, -3, -4
Page 6 May 29, 1996 Revised
BASE ASSEMBLY NO. 375769-1 & -4
DESCRIPTION AND INSTALLATION INSTRUCTIONS
Description
The base is designed for use in assembling a
composite Series 2000 Wire Feeder. It is a compo-
nent which makes it possible to bring together a
Control Box and Feedhead Assembly (which have
their own TIP Instruction Sheets), and a Wire Spool
Support Assembly.
Installation
The illustration below shows the mounting of the
Control Box, Feedhead Assembly, and the Wire
Spool Support Assembly.
1. To mount the Control Box Assembly, align holes
in the base with the grommets (in the Control Box
bottom panel), insert the self-tapping mounting
screws through the holes in the base, into the nylon
grommets.
2. Tighten the screws in place, which will expand
the nylon grommets in the holes in the Control Box
bottom.
NOTE: The Feedhead Assembly is se-
cured to the Control Box, and does not
bolt directly to the base.
3. Align four holes in the bottomflange on the Wire
Spool Support with four holes in the base (as shown
in illustration) and insert four capscrews through the
holes in the base and stiffener (underneath the
base) and secure in place with the four hex nuts.
TIP-127
BASE ASSEMBLY NO. 375769-1 & -4
May 17, 1996 Revised Page 1
This page intentionally left blank.
TIP-127
BASE ASSEMBLY NO. 375769-1 & -4
Page 2 May 17, 1996 Revised
INSTRUCTION SHEET - Installation of
Wire “Reel” or “Spool” on the Support
The wire feeder will be shipped from the factory
with a wire spool kit 870058 and a wire reel/spool
support assembly 870060-X. An “optional” wire reel
kit 870059 is also available.
WARNING: Mount spool with
hub nut angled upward (see Fig-
ure 1). Hub nut may detachcaus-
ing personal injury from falling
wire coil spool if improperly
mounted.
1. To install the Wire Reel/Spool Support Assem-
bly (870060-X) onto the Baseplate:
a. Use the four 1/4-20 x 7/8" screws, the four
hex keps nuts, and the two flat washers to fasten
the support (1) to the wire feeder base.
2. To install the Wire Spool Kit (870058):
a. Mount the shaft (6) in the lower hole (if using
a 30-45 lb. spool) or in the upper hole (if using a 60
lb. spool) of the support (1). Make sure the 1/2-13
hex nut (2) is securely tightened on the shaft (6).
See Figure 2.
b. Mount the Wire Spool Hub (13) on the Shaft (6).
c. Install the spool tension spacer, compression
spring, spacer, and the hub tension screw.
d. Place a wire spool on the hub (13). Align the
positioning pin on the hub with the hole in the wire
spool so that the wire feeds from the bottom of the
coil. See Figure 3.
e. Install the wire spool hub nut (17) and tighten
until the spring ball plunger falls into the dimple on
the wire spool hub.
f. Adjust the compression spring tension by use
of the hub tension screw until the proper reel drag
is achieved.
Figure 1
Figure 2
Figure 3
I-169
December 1, 1997 Revised 1
3. To install the Wire Reel Kit (870059):
a. Mount the shaft (6) in the upper hole of the
support (1) to assure proper clearance for the wire
reel (7). See Figure 4.
b. Mount the wire reel (7) on the shaft (6).
c. Install the wire reel washer, the steel wire reel
washer, compression spring, “T” wire reel washer,
and the drag adjusting screw.
d. Loosen the wing nuts holding the movable
arms. Rotate the arms inward towards the center of
the reel (7). Place the coiled wire on the reel so the
wire feeds from the bottom of the coil to the wire
feeder. See Figure 5.
e. Reposition the movable arms outward and
tighten the wing nuts.
f. Tighten the drag adjusting screw until the
desired reel drag is achieved.
Figure 4
Figure 5
I-169
2 December 1, 1997 Revised
I-169
December 1, 1997 Revised 3
This page intentionally left blank.
I-169
4 December 1, 1997 Revised
I-169
December 1, 1997 Revised 5
This page intentionally left blank.
I-169
6 December 1, 1997 Revised
I-169
December 1, 1997 Revised 7
This page intentionally left blank.
I-169
8 December 1, 1997 Revised
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.
MODEL
NUMBER
SPECIFICATION
NUMBER
SCHEMATIC/
CONNECTION
DIAGRAM OPTIONS
SYSTEM
OUTLINE
2460
Heavy Duty
CC/CV
6877A-1, -2 376784B
Sheet 1 & 2
376827 376823
6877B-1, -2 376784B
Sheet 1 & 2
376827 376823
430429-249
DIAGRAMS
June 17, 1997 Revised
2 10/7/2002 Revised
SCHEMATIC AND CONNECTION DIAGRAM 1 OF 2
1
2
3
2A
3A 4
J2 J1 J3
2
9

B
L
2
A
1 2
K
E
Y
3 4
2
8

O
R
2
7

Y
L
2
A
2
A
54321 5
9
5

W
T
-
R
D
9 9
4

B
R
3

B
L
43
2
2

G
N
21
2
1

W
T
K
E
Y
7
6

W
T
-
B
R
5
8 9
7

W
T
-
B
K
8

W
T
-
Y
L
35
9

B
L
-
B
K
3
6
3
A
1
0

B
K
6
1
1

R
D
1
1
MOTOR CONTROL P.C. BOARD
+
CR1
-
1 WT
1
17 YL
5
2 GN
1
12 BL-GN
5
9 BL-BK
1
8 WT-YL
1
S2
GAS VALVE
P.C. BOARD 5
11
1
27 YL
25 BR
4
3
28 OR
2
1
11
26 RD
6
KEY
29 BL
1
1
BK(M)
10 BK
1
14 RD-WT
15 BL-RD
10
F2
F1
6 5
-
-
1
2
1
0
A
B
D
C
6
F
E
7 8
7 8 6
J1
FACING INSIDE REAR OF CASE
FACING INSIDE
BOTTOM OF CASE
10/7/2002 Revised 3
PAGES AFFECTED DATE
REVISION CHART
ECN NO. REV
DIAGRAM, CONNECTION & SCHEMATIC
2460 HEAVY DUTY WIRE FEEDER
NONE
1 OF 2
FULL TLT JLC 7-29-91
376784B 10-7-02
TLT TLT 8-15-91
150 8-91
TECH PUB
376784B
5
9
8
10
11
6
7
8 7 6 5 4 3 2 1
4 BK
12 BL-GN
14 RD-WT
21 OR-WT
7 WT-BK
23 WT-GN
7 8
2 1
4 8
3 BL
4 BR
5 WT-RD
1
1
1
R1
4 BK
5
TO WORK
23 WT-GN
5
21 OR-WT
5
J4
15 BL-RD
4
11
16 BR-BK
S1
16 BR-BK
10
FEEDHEAD
2A
2A
B1
L1
26 RD
25 BR
11 RD
1
TB1
BK
RD
(M)
3A
A) PP1192 8-14-96
6 WT-BR
1
17 YL
2
13 YL-BK
18 BK-BL
22 RD-BL
20 BK-OR
CHANGE RECORD
E.C. No. DATE
PLOT DATE
CHECKED APPROVED RECORDS ITEMTYPE
DESIGNED DRAWN DATE SCALE
COMM. CLS.
DESCRIPTIVE DATA
TITLE
MATERIAL SPEC.
MATERIAL NO.
ACTIVITY
FINISH CODE PER
REPLACED BY REPLACES
QUANTITY-U.M.
DWG. NO. SIZE
C
FRACT.
INCH ±
SHEET
FILE NAME
1 2 3 5 4
DISTRIBUTION TABLE
OUTSIDE DISTR.
A
B
C
D
E
F
5 4 3 2 1
CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.
TROY, OHIO 45373, U.S.A.
ANGLES ± 3˚
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOWAPPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.
DECIMAL-INCH
0.00 ± 0.1mm
0.0 ± 0.4mm
0. ± 1.0mm
.000 ± .003
.00 ± .02
DO NOT SCALE DRAWING
.0 ± .1
A THERMADYNE Company R
R
FACING INSIDE FRONT OF CASE
6-6-97 1472 B 1, 2
4 10/7/2002 Revised
SCHEMATIC AND CONNECTION DIAGRAM 2 OF 2
TO FEEDHEAD
S1
TO WORK
J1-1
J1-2
J1-3
J1-4
J1-5
J1-7
J1-8
TB1-6
TB1-8
R1
CR1
J
2
-
2
J
2
-
5
TB1-5
TB1-7
TB1-2
TB1-3 TB1-4
TB1-1
F1
J4
A
B
D
C
6 5
F
E
7 8
7 8 5 6
10/7/2002 Revised 5
LEGEND
L1
J
1
-
6
B1
S2
J
3
-
1
J
1
-
1
GAS VALVE
P.C. BOARD
B1
CR1
F1
F2
J1
J2
J3
R1
S1
J4
S2
TB1
L1 GAS VALVE, 12VDC
TERMINAL BLOCK
SWITCH, CC/CV
RECEPTACLE, GUN SWITCH
SWITCH, ON-OFF
POTENTIOMETER, 10KOHMS, 2W
RECEPTACLE, MOTOR CONTROL BOARD
RECEPTACLE, METER OPTION
RECEPTACLE, MOTOR CONTROL BOARD,
FUSE, SLOW BLOW, 5A
FUSE, SLOW BLOW, 7A
RECTIFIER, BRIDGE
MOTOR, WIRE FEED
J
1
-
9
J
1
-
1
0
J1-12
J1-11
J2-1
J2-3
F2
MOTOR CONTROL
P.C. BOARD
J
1
-
3
J
3
-
2
J
1
-
5
J
3
-
3
J
1
-
2
J
3
-
4
J
1
-
4
GAS VALVE BOARD
DIAGRAM, CONNECTION & SCHEMATIC
2460 HEAVY DUTY WIRE FEEDER
NONE
2
FULL TLT JLC 6-6-97
376784B2 11-6-97
TLT TLT 8-15-91
150 8-91
TECH PUB
376784B
CHANGE RECORD
E.C. No. DATE
PLOT DATE
CHECKED APPROVED RECORDS ITEMTYPE
DESIGNED DRAWN DATE SCALE
COMM. CLS.
DESCRIPTIVE DATA
TITLE
MATERIAL SPEC.
MATERIAL NO.
ACTIVITY
FINISH CODE PER
REPLACED BY REPLACES
QUANTITY-U.M.
DWG. NO. SIZE
C
FRACT.
INCH ±
SHEET
FILE NAME
1 2 3 4
DISTRIBUTION TABLE
OUTSIDE DISTR.
A
B
C
D
E
F
4 3 2 1
CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.
TROY, OHIO 45373, U.S.A.
ANGLES ± 3˚
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.
DECIMAL-INCH
0.00 ± 0.1mm
0.0 ± 0.4mm
0. ± 1.0mm
.000 ± .003
.00 ± .02
DO NOT SCALE DRAWING
.0 ± .1
A THERMADYNE Company R
R
April 14, 2005 Revised
LIMITED WARRANTY
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of its
authorized distributors hereafter “Purchaser” 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: THERMALARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT
OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS 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, strict 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 THERMALARC’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMALARC PRODUCT.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-
AUTHORIZED PERSONS.

POWER SUPPLIES ALL OTHER LABOR
POWER SUPPLIES
MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 3 YEAR
ORIGINAL MAIN POWER RECTIFIER 3 YEARS 3 YEAR
CONTROL PC BOARD 3 YEARS 3 YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT 1 YEAR 1 YEAR
NOT LIMITED TO: CONTACTORS, RELAYS, SOLENOIDS, 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 EXCHANGES, 1 YEAR 1 YEAR
AND ACCESSORY EQUIPMENT
TORCH AND LEADS 180 DAYS 180 DAYS
REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS


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.
NOTE: Dragster 85® excluded from this policy. Refer to Dragster 85 warranty in Dragster 85 Owner’s Manual.
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 purchaser’s notice of any Warranty Claim. 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 Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous Thermal
Arc warranties. Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.
September 27, 2004