THERMAL ARC Lightweight Welding Cart Assembly instruction

Manual 0-5008

Rev AC

82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermalarc.com

General Information

The Thermal Arc Lightweight Welding Cart is designed
to easily transpor t a small-to-medium size power
supply, wire feeder, gas bottle*, welding torch and
various arc/air accessories. These instructions will
guide you through the proper assembly of the cart.

*Maximum 44-in.(112cm) high x 7-in.(18cm)
diameter.

Recommended Tools

• 5mm allen wrench (actual size may vary)

• 10mm wrench (actual size may vary)

• Pliers

Supplied Parts

The following components are included in this kit:

Lightweight Welding Cart

Catalog # W4011500

Assembly Instructions

ITEM # DESCRIPTION QTY

1 SHELF,LOWER 1
2 BRACE, SUPPORT 2
3 BRACKET, CABLE 1
4 BRACKET, POWER SUPPLY, REAR 1
5 BRACKET, POWER SUPPLY, SIDE 2
6 HANDLE, GRIP AND CASTER 2
7 PANEL, REAR 1
8 SHELF, UPPER 1

9 WHEEL, PLASTIC, 8" OD 2
10 AXLE, CART 1
11 WASHER 2
12 COTTOR PIN 2
13 3mm * 26mm * 700mm CHAIN 1
14 LONG 6mm ALLEN BOLT 4
15 SHORT 6mm ALLEN BOLT 8
16 6mm SELF-LOCKING NUT 12
17 DECAL, MAX BOTTLE SIZE 1
18 DECAL, DO NOT LIFT 1

3547

18

6

Art # A-08521

© 2007 by Thermadyne Industries

8

17

13

2

9

11

1

10

12

November 12, 2007 1 0-5008_AC

WELDING CART ASSEMBLY INSTRUCTIONS

A. Assemble the Base

1. Place the lower shelf (1) on its left side.

2. Position the rear panel (7) inside the lower shelf
and line up the holes as shown below.

3. Insert 2 of the 6mm short bolts (15) through the
holes. Thread a nut (16) on to each bolt and fasten
until finger-tight.

Art # A-08522_AB

15

7

C. Attach Right Side Brace

1. Take one of the side braces (2) and line up its three
holes with those in the assembly.

2. Insert a 6mm short bolt (15) through each hole and
hand tighten a nut (16) to each.

15

2

Art # A-08524_AB

16

1

16

B. Install Upper Shelf

Keep the assembly on its left side and slide the tabs of
the upper shelf (8) into the slots of the rear panel as
shown.

8

D. Attach Right Handle-Bar-Caster

1. Attach the right side handle-bar-caster assembly
using two 6mm long bolts (14) as shown.

2. Thread a nut (16) on to each bolt and fasten until
finger-tight.

6

14

Art # A-08525

Art # A-08523_AB

November 12, 2007 2 0-5008_AC

WELDING CART ASSEMBLY INSTRUCTIONS

E. Snug All Hardware

Snug all the fasteners at this time but do not fully
tighten. Use a 5mm allen wrench on the bolts and a
10mm wrench on the nuts.

F. Attach Left Side Components

Turn the assembly over on its left side and repeat the
procedure in steps C and D but this time include the
cable bracket (3) as shown.

3

H. Insert Axle

1. Insert the axle (10) through the holes in the bottom
of the two side braces (2) as shown.

2. Apply "Max Bottle Size" decal (17) as shown.

17

2

10

Art # A-08526

G. Tighten All Hardware

Fully tighten all the fasteners securely at this time but
do not overtighten. Use a 5mm allen wrench on the
bolts and a 10mm wrench on the nuts.

Art# A-08527

I. Install Wheels on Axle

1. Center the axle between the two braces.

2. Slide a wheel (9) over the axle followed by a washer
(11).

9

11

Art # A-08528

November 12, 2007 3 0-5008_AC

WELDING CART ASSEMBLY INSTRUCTIONS

J. Fasten Wheels

1. Insert a cotter pin (12) through the hole in the axle
from the top down as shown.

2. Spread the cotter pin apart using a pair of pliers.

3. Repeat steps I and J with the other wheel.

12

Art # A-08529

L. Hang Chain

1. Insert one end of the chain (13) thr ough the
appropriate level hole on the left side of the rear
panel and secure it by turning and sliding the second
link into the slot (top hole is shown).

2. Wrap the chain around the gas bottle and pull the
other end through the same level hole on the right
side of the rear panel.

3. Pull the chain as tight as it will go and secure it by
turning and sliding the closest link into the slot.

13

K. Install Brackets

1. Insert the side (5) and rear (4) support brackets
into one of the three sets of slots on the top shelf.

2. If necessary, move the brackets into the other slots
to adjust how they fit to your power supply or wire
feeder.

3. Apply "Do Not Lift" decal (18) as shown.

45

18

5

Art # A-08531

Art # A-08530

November 12, 2007 4 0-5008_AC

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: [phone]
Fax: [phone]

Thermadyne Italy

OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

World Headquarters

Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017

Telephone: [phone]
FAX:
Email: [e-mail]

[phone]

www.thermalarc.com