Thermal Arc Preditor Pro

Date 06/04/02 KLA Manual 430429-498

Predator Pro

DC CC/CV Welding Generator

STICKMIG

AUXILIARY POWER

Service Manual

Date 06/04/02 KLA Manual 430429-498

Date 06/04/02 KLA Manual 430429-498

Table of ContentsSECTION 1: GENERAL INFORMATION ................................................................................................................................4

1.01 Notes, Cautions and Warnings ........................................................................................................................................41.02 Important Safety Precautions ..........................................................................................................................................41.03 Publications .....................................................................................................................................................................51.04 Note, Attention et Avertissement ....................................................................................................................................61.05 Precautions De Securite Importantes...............................................................................................................................61.06 Documents De Reference................................................................................................................................................8

SECTION 2: TECHNICAL SPECIFICATIONS....................................................................................................................102.01 Specifications .................................................................................................................................................................102.02 Volt-Amp Curve.............................................................................................................................................................102.03 Duty Cycle .....................................................................................................................................................................102.04 Front Panel Descriptions ................................................................................................................................................112.05 Dimensions and Weight .................................................................................................................................................122.06 Maximum Welding Generator Operating Angles...........................................................................................................122.07 Installing Welding Generator .........................................................................................................................................122.08 Location..........................................................................................................................................................................132.09 Air Flow Clearance ........................................................................................................................................................132.10 Generator Auxiliary Power System................................................................................................................................142.11 Wiring Optional 230 Volt Plug ......................................................................................................................................142.12 Grounding The Generator ..............................................................................................................................................152.13 When Connecting To Home, Shop, or Farm Wiring......................................................................................................152.14 Auxiliary Power Requirements ......................................................................................................................................162.15 Simultaneous Welding and Power..................................................................................................................................172.16 Selecting and Preparing Weld Output Cables ................................................................................................................17

SECTION 3: TROUBLE SHOOTING GUIDE.........................................................................................................................193.01 There Is No Auxiliary Voltage and/or Welding Current ................................................................................................193.02 The Generator Is De-Energized when Load is connected ..............................................................................................203.03 Excessive Fall of Voltage When The Load is Connected ..............................................................................................203.04 Single Phase Receptacle Out Of Balance When at Idling ..............................................................................................203.05 Insufficient Welding Current..........................................................................................................................................203.06 The Battery Runs down Frequently................................................................................................................................21

SECTION 4: CIRCUIT TESTING ............................................................................................................................................224.01 Checking the Resistance of the Stator Windings............................................................................................................224.02 Replacing the Stator .......................................................................................................................................................224.03 Excitation Capacitors .....................................................................................................................................................234.04 Output Rectifier and SCR...............................................................................................................................................234.05 Test for PC Board P95031 .............................................................................................................................................234.06 PC Board Adjustment procedure....................................................................................................................................244.07 Calibration procedure for idle adjustment ......................................................................................................................254.08 Automatic Idle Circuit....................................................................................................................................................254.09 Tests points for PC Board GS9712/R.............................................................................................................................264.10 Engine Oil Shut-Down Circuit Tests..............................................................................................................................264.11 Engine Charge Circuit Shut-Down Test.........................................................................................................................26

SECTION 5 PARTS LIST .........................................................................................................................................................275.01 Stator Parts .....................................................................................................................................................................275.02 Front Panel .....................................................................................................................................................................295.03 Sheet Metal Parts............................................................................................................................................................315.05 Engine Related Parts ......................................................................................................................................................335.06 Common Engine Part Numbers......................................................................................................................................34

SECTION 6: Schematics............................................................................................................................................................356.01 System Schematic ..........................................................................................................................................................366.02 Idle PC Board 11-3449...................................................................................................................................................38

4 GENERAL INFORMATION

SECTION 1: GENERALINFORMATION

1.01 Notes, Cautions andWarnings

Throughout this manual, notes, cautions, andwarnings are used to highlight important information.These highlights are categorized as follows:

NOTE

An operation, procedure, or backgroundinformation which requires additional emphasis oris helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, maycause damage to the equipment.

WARNING

A procedure which, if not properly followed, maycause injury to the operator or others in theoperating area.

1.02 Important SafetyPrecautions

WARNING

OPERATION AND MAINTENANCE OF ARCWELDING EQUIPMENT CAN BEDANGEROUS AND HAZARDOUS TO YOURHEALTH.

To prevent possible injury, read, understand andfollow all warnings, safety precautions andinstructions before using the equipment. Call 1-603-298-5711 or your local distributor if you haveany questions.

GASES AND FUMES

Gases and fumes produced during the Arcwelding/cutting process can be dangerous andhazardous to your health.

• Keep all fumes and gases from the breathing area.Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is notadequate to remove all fumes and gases.

• The kinds of fumes and gases from the arcwelding/cutting depend on the kind of metalbeing used, coatings on the metal, and thedifferent processes. You must be very carefulwhen cutting or welding any metals which maycontain one or more of the following:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium Manganese Vanadium

• Always read the Material Safety Data Sheets(MSDS) that should be supplied with the materialyou are using. These MSDSs will give you theinformation regarding the kind and amount offumes and gases that may be dangerous to yourhealth.

• For information on how to test for fumes andgases in your workplace, refer to item 1 inSubsection 1.03, Publications in this manual.

• Use special equipment, such as water or downdraft welding/cutting tables, to capture fumesand gases.

• Do not use the welding torch in an area wherecombustible or explosive gases or materials arelocated.

• Phosgene, a toxic gas, is generated from thevapors of chlorinated solvents and cleansers.Remove all sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The arc weldingprocess uses and produces high voltage electricalenergy. This electric energy can cause severe or fatalshock to the operator or others in the workplace.

• Never touch any parts that are electrically “live”or “hot.”

• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircuit.

• Repair or replace all worn or damaged parts.• Extra care must be taken when the workplace is

moist or damp.


• Install and maintain equipment according to NECcode, refer to item 4 in Subsection 1.03,Publications.

• Disconnect power source before performing anyservice or repairs.

• Read and follow all the instructions in theOperating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks,or the arc weld.

• Be sure there is no combustible or flammablematerial in the workplace. Any material thatcannot be removed must be protected.

• Ventilate all flammable or explosive vapors fromthe workplace.

• Do not cut or weld on containers that may haveheld combustibles.

• Provide a fire watch when working in an areawhere fire hazards may exist.

• Hydrogen gas may be formed and trapped underaluminum workpieces when they are cutunderwater or while using a water table. DONOT cut aluminum alloys underwater or on awater table unless the hydrogen gas can beeliminated or dissipated. Trapped hydrogen gasthat is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Arcwelding/cutting processes can cause noise levels toexceed safe limits. You must protect your ears fromloud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wearprotective ear plugs and/or ear muffs. Protectothers in the workplace.

• Noise levels should be measured to be sure thedecibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item1 in Subsection 1.03, Publications, in this manual.

ARC WELDING RAYS

Arc Welding/Cutting Rays can injure your eyes andburn your skin. The arc welding/cutting processproduces very bright ultra violet and infra red light.These arc rays will damage your eyes and burn yourskin if you are not properly protected.

• To protect your eyes, always wear a weldinghelmet or shield. Also always wear safety glasseswith side shields, goggles or other protective eyewear.

• Wear welding gloves and suitable clothing toprotect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.Use protective booths, screens or shields.

• Use the shade of lens as recommended inSubsection 1.03, item 4.

1.03 PublicationsRefer to the following standards or their latestrevisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS,29CFR 1910, obtainable from the Superintendent ofDocuments, U.S. Government Printing Office,Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING ANDCUTTING, obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARCWELDING AND GAS WELDING AND CUTTING,obtainable from the Superintendent of Documents,U.S. Government Printing Office, Washington, D.C.20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOROCCUPATION AND EDUCATIONAL EYE ANDFACE PROTECTION, obtainable from AmericanNational Standards Institute, 1430 Broadway, NewYork, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’SSAFETY-TOE FOOTWEAR, obtainable from theAmerican National Standards Institute, 1430Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THEUSE OF CUTTING AND WELDING PROCESSES,obtainable from American National StandardsInstitute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTINGCONTAINERS WHICH HAVE HELDCOMBUSTIBLES, obtainable from American


Welding Society, 550 N.W. LeJeune Rd, Miami, FL33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMSFOR WELDING, CUTTING AND ALLIEDPROCESSES, obtainable from the National FireProtection Association, Batterymarch Park, Quincy,MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICALCODE, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDINGPROCESSES, obtainable from the National FireProtection Association, Batterymarch Park, Quincy,MA 02269

11.CGA Pamphlet P-1, SAFE HANDLING OFCOMPRESSED GASES IN CYLINDERS, obtainablefrom the Compressed Gas Association, 1235Jefferson Davis Highway, Suite 501, Arlington, VA22202

12. CSA Standard W117.2, CODE FOR SAFETY INWELDING AND CUTTING, obtainable from theCanadian Standards Association, Standards Sales,178 Rexdale Boulevard, Rexdale, Ontario, CanadaM9W 1R3

13. NWSA booklet, WELDING SAFETYBIBLIOGRAPHY obtainable from the NationalWelding Supply Association, 1900 Arch Street,Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1,RECOMMENDED SAFE PRACTICES FOR THEPREPARATION FOR WELDING AND CUTTINGOF CONTAINERS AND PIPING THAT HAVEHELD HAZARDOUS SUBSTANCES, obtainablefrom the American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FORRESPIRATORY PROTECTION, obtainable fromAmerican National Standards Institute, 1430Broadway, New York, NY 10018

1.04 Note, Attention etAvertissement

Dans ce manuel, les mots “note,” “attention,” et“avertissement” sont utilisés pour mettre en relief desinformations à caractère important. Ces mises en reliefsont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignementgénéral sur lequel il importe d’insister davantageou qui contribue à l’efficacité de fonctionnement dusystème.

ATTENTION

Toute procédure pouvant résulterl’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessuresde l’opérateur ou des autres personnes se trouvantdans la zone de travail en cas de non-respect de laprocédure en question.

1.05 Precautions De SecuriteImportantes

AVERTISSEMENT

L’OPÉRATION ET LA MAINTENANCE DUMATÉRIEL DE SOUDAGE À L’ARC AU JETDE PLASMA PEUVENT PRÉSENTER DESRISQUES ET DES DANGERS DE SANTÉ.

Il faut communiquer aux opérateurs et aupersonnel TOUS les dangers possibles. Afind’éviter les blessures possibles, lisez, comprenez etsuivez tous les avertissements, toutes lesprécautions de sécurité et toutes les consignes avantd’utiliser le matériel. Composez le + 603-298-5711ou votre distributeur local si vous avez desquestions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet deplasma peuvent présenter des risques et des dangersde santé.

• Eloignez toute fumée et gaz de votre zone derespiration. Gardez votre tête hors de la plumede fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation enair si l’aération fournie ne permet pas d’éliminerla fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arcde plasma dépendent du genre de métal utilisé,des revêtements se trouvant sur le métal et desdifférents procédés. Vous devez prendre soinlorsque vous coupez ou soudez tout métal


pouvant contenir un ou plusieurs des élémentssuivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre séléniumbéryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécuritédes matières (sigle américain “MSDS”); celles-cidevraient être fournies avec le matériel que vousutilisez. Les MSDS contiennent desrenseignements quant à la quantité et la naturede la fumée et des gaz pouvant poser des dangersde santé.

• Pour des informations sur la manière de tester lafumée et les gaz de votre lieu de travail,consultez l’article 1 et les documents cités à lapage 5.

• Utilisez un équipement spécial tel que des tablesde coupe à débit d’eau ou à courant descendantpour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dansune zone où se trouvent des matières ou des gazcombustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par lafumée provenant des solvants et des produits denettoyage chlorés. Eliminez toute source de tellefumée.

CHOC ELECTRIQUELes chocs électriques peuvent blesser ou même tuer. Leprocédé au jet de plasma requiert et produit del’énergie électrique haute tension. Cette énergieélectrique peut produire des chocs graves, voiremortels, pour l’opérateur et les autres personnes sur lelieu de travail.

• Ne touchez jamais une pièce “sous tension” ou“vive”; portez des gants et des vêtements secs.Isolez-vous de la pièce de travail ou des autresparties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ouendommagée.

• Prenez des soins particuliers lorsque la zone detravail est humide ou moite.

• Montez et maintenez le matériel conformémentau Code électrique national des Etats-Unis. (Voirla page 5, article 9.)

• Débranchez l’alimentation électrique avant touttravail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuelde consignes.

INCENDIE ET EXPLOSIONLes incendies et les explosions peuvent résulter desscories chaudes, des étincelles ou de l’arc de plasma.Le procédé à l’arc de plasma produit du métal, desétincelles, des scories chaudes pouvant mettre le feuaux matières combustibles ou provoquer l’explosionde fumées inflammables.

• Soyez certain qu’aucune matière combustible ouinflammable ne se trouve sur le lieu de travail.Protégez toute telle matière qu’il est impossiblede retirer de la zone de travail.

• Procurez une bonne aération de toutes les fuméesinflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneursayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travaildans une zone présentant des dangersd’incendie.

• Le gas hydrogène peut se former ou s’accumulersous les pièces de travail en aluminiumlorsqu’elles sont coupées sous l’eau ou sur unetable d’eau. NE PAS couper les alliages enaluminium sous l’eau ou sur une table d’eau àmoins que le gas hydrogène peut s’échapper ouse dissiper. Le gas hydrogène accumuléexplosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuventblesser vos yeux et brûler votre peau. Le procédé àl’arc de plasma produit une lumière infra-rouge et desrayons ultra-violets très forts. Ces rayons d’arc nuirontà vos yeux et brûleront votre peau si vous ne vousprotégez pas correctement.

• Pour protéger vos yeux, portez toujours un casqueou un écran de soudeur. Portez toujours deslunettes de sécurité munies de parois latérales oudes lunettes de protection ou une autre sorte deprotection oculaire.

• Portez des gants de soudeur et un vêtementprotecteur approprié pour protéger votre peaucontre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes deprotection en bon état. Remplacez toute lentillesale ou comportant fissure ou rognure.


• Protégez les autres personnes se trouvant sur lazone de travail contre les rayons de l’arc enfournissant des cabines ou des écrans deprotection.

• Respectez le teint de lentille recommandé dans learticle 4, page 5.

• Hydrogen gas may be present under aluminumworkpieces during the cutting process whenbeing cut underwater or using a water table. DONOT cut aluminum underwater or on a watertable unless the hydrogen gas can be eliminatedas the hydrogen gas may detonate.

BRUIT

Le bruit peut provoquer une perte permanente del’ouïe. Les procédés de soudage à l’arc de plasmapeuvent provoquer des niveaux sonores supérieursaux limites normalement acceptables. Vous dú4ez vousprotéger les oreilles contre les bruits forts afin d’éviterune perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts,portez des tampons protecteurs et/ou desprotections auriculaires. Protégez également lesautres personnes se trouvant sur le lieu detravail.

• Il faut mesurer les niveaux sonores afin d’assurerque les décibels (le bruit) ne dépassent pas lesniveaux sûrs.

• Pour des renseignements sur la manière de testerle bruit, consultez l’article 1, page 5.

1.06 Documents DeReference

Consultez les normes suivantes ou les révisions lesplus récentes ayant été faites à celles-ci pour de plusamples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAILET DE PROTECTION DE LA SANTÉ, 29CFR1910, disponible auprès du Superintendent ofDocuments, U.S. Government Printing Office,Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DESOPÉRATIONS DE COUPE ET DE SOUDAGE,disponible auprès de la Société Américaine deSoudage (American Welding Society), 550 N.W.LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DESOPÉRATIONS DE COUPE ET DE SOUDAGE À

L’ARC ET AU GAZ, disponible auprès duSuperintendent of Documents, U.S. GovernmentPrinting Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POURLA PROTECTION DES YEUX ET DU VISAGEAU TRAVAIL ET DANS LES ECOLES,disponible de l’Institut Américain des NormesNationales (American National StandardsInstitute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LESCHAUSSURES PROTECTRICES, disponibleauprès de l’American National StandardsInstitute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DESINCENDIES LORS DE L’EMPLOI DEPROCÉDÉS DE COUPE ET DE SOUDAGE,disponible auprès de l’American NationalStandards Institute, 1430 Broadway, New York,NY 10018

7. Norme A6.0 de l’Association Américaine duSoudage (AWS), LE SOUDAGE ET LA COUPEDE CONTENEURS AYANT RENFERMÉ DESPRODUITS COMBUSTIBLES, disponible auprèsde la American Welding Society, 550 N.W.LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour laProtection contre les Incendies (NFPA), LESSYSTEMES À GAZ AVEC ALIMENTATION ENOXYGENE POUR LE SOUDAGE, LA COUPE ETLES PROCÉDÉS ASSOCIÉS, disponible auprèsde la National Fire Protection Association,Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUENATIONAL, disponible auprès de la NationalFire Protection Association, Batterymarch Park,Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DECOUPE ET DE SOUDAGE, disponible auprès dela National Fire Protection Association,Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANSRISQUE DES GAZ COMPRIMÉS ENCYLINDRES, disponible auprès de l’Associationdes Gaz Comprimés (Compressed GasAssociation), 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉPOUR LE SOUDAGE ET LA COUPE, disponibleauprès de l’Association des NormesCanadiennes, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada, M9W 1R3


13. ivret NWSA, BIBLIOGRAPHIE SUR LASÉCURITÉ DU SOUDAGE, disponible auprès del’Association Nationale de Fournitures deSoudage (National Welding Supply Association),1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine deSoudage, RECOMMANDATIONS DEPRATIQUES SURES POUR LA PRÉPARATIONÀ LA COUPE ET AU SOUDAGE DE

CONTENEURS ET TUYAUX AYANTRENFERMÉ DES PRODUITS DANGEREUX ,disponible auprès de la American WeldingSociety, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DEPROTECTION RESPIRATOIRE, disponibleauprès de l’American National StandardsInstitute, 1430 Broadway, New York, NY 10018

10 TECHNICAL SPECIFICATIONS

SECTION 2: TECHNICAL SPECIFICATIONS2.01 Specifications

The Thermal Arc Predator Pro is a gasoline engine driven DC welding generator with selectable Constant Current (CC) andConstant Voltage (CV) output characteristics. This unit is designed for use with Shielded Metal Arc Welding (SMAW), Gas MetalArc Welding (GMAW), and GAS Tungsten Arc Welding - (GTAW) processes.

SpecificationsDC

Amperage Range 15 – 270Duty Cycle 270 @ 60%AC/DC welding current 250 @ 100%Volt Range CV Mode 16 – 30OCV CC Mode 70 VDCAuxiliary PowerSingle Phase 115 2ea GFCI Duplex Receptacles 3.5KvaSingle Phase 115/240 8.5KvaThree Phase 460 10KvaEngineMake/Type HONDAModel series GX 620K1Number of cylinders 2Displacement 614 cc.Power 20 HPEngine Speed 3750 rpm no loadEngine speed 2900 rpm IdleCooling system AirOil capacity 1.5 l. - 0,42 gl.Fuel capacity 37.5 l. - 10 gl.Fuel consumption 5.2 l/h – 1.4 gl./HrBattery 12V 340A

2.02 Volt-Amp Curve NOTEVolt-ampere curves show the voltage and amperage outputcapabilities of the welding power source. Curves of othersettings will fall between the curves shown.

2.03 Duty CycleThe duty cycle of a welding generator is the percentage of aten-minute period that a welding generator can be operatedat a given output without causing overheating and damage ofthe unit. This unit is rated at 60 percent duty cycle whenoperated at 270 amperes. The unit can be operated at 270amperes for six consecutive minutes, but it must operate atno load for the remaining four minutes to allow propercooling. If the welding amperes decrease, the duty cycleincreases. If the welding amperes are increased beyond ratedoutput, the duty cycle will decrease.


CAUTION: CONTINUAL EXCEEDING OF DUTYCYCLE RATINGS CAN CAUSE DAMAGE TO THEWELDING POWER SOURCE.

2.04 Front Panel Descriptions

1 Amperage/Voltage Control – detects the desiredAmperage or Voltage (depending on mode) withinthe entire range of the welding generator. The scalesurrounding the control represents approximateactual values.

2 Battery Charge Lamp - When the RUN/STOPSwitch is turned on the Battery Charge Lampwill Glow. For normal operation when the engine isrunning the Battery Charge Lamp will be off.Should the Charging circuit or Battery fail theBattery Warning Lamp will Turn-on and the enginewill shut off.

3 Oil level Lamp - When the RUN/STOP Switch isturned on the Oil level Lamp willNot Glow. Should the oil sensor in the enginedetect a low oil condition the Oil levelLamp will turn-on and the engine will shut off.

4 Weld Control – Local / Remote Switch5 Process Selector switch : CC/CV - Allows the

operator to select the CC (Constant Current)process or CV (Constant voltage) process.

6 Arc Control - The Arc Control is use in the SMAWmode only. Rotate the control clockwise to increasethe short circuit current available to control thewelding arc.

7 Serial number

8 Welding Receptacle: Electrode - Positive outputwelding connection for CC (Constant Current) andCV (Constant Voltage).

9 14 Pin receptacle - Used for remote Contactor,amperage controls wire feeder control.

10 115V 3A Circuit breaker - Push to reset. Controls115V power source for wire feedersControlled through the 14 pin receptacle.

11 Welding receptacle Work : Negative output weldingconnection for CV (Constant voltage)MIG.

12 Welding Receptacle Work: Negative output weldingconnection for CC (Constant current)STICK

1 115V 20A Circuit Breakers – Push to reset.Controls 115V power source for the 115V duplexGFCI receptacles

2 115V Single Phase GFCI Receptacle - Supplies60 Hz single-phase power at weld/power speed.

3 230/115V 50A Circuit Breakers - Push to reset.Controls 230/115V power source for the230/115V receptacle (4).

4 230/115V Single Phase Receptacle - Supplies 60Hz single-phase power at weld/power speed.

5 Fuel Gauge – Monitors fuel level6 Engine : Auto/High switch - When in Auto the

unit will idle until a load is applied. In Highposition the engine will operate above idle RPM.

7 Engine RUN/STOP Switch - Place in the RUNposition to operate generator. Use the STARTbutton to start the engine. To shut off engine placeswitch in stop position.

8 START button- Used to start the engine. Set theRUN/START switch to RUN, push STARTbutton to start the engine. When engine startsrelease button.

9 Hour meter – Monitors Time in hours when theengine is on.

10 Choke - Pull knob out engages Choke. Push knobin for normal operation.

11 Earth connection - used to earth ground thegenerator for auxiliary power.


1 13A Circuit breaker - 3 poles circuit breakercontrols 460V three phase power source.

2 460V Output - Access for three phase 460V 60 Hzconnections. Connect Line1, 2 and 3 tothe output side of the circuit breaker and theground to the bolt mounted beside the circuitbreaker.

2.05 Dimensions and Weight

Height 710mm 27.9”Width 530mm 20.86”Length 1080mm 42.52”A 15mm .59”B 1050mm 41.34”C 34.5mm 1.36”D 424mm 16.69”E 10.5mm

Dia..41” Dia.

Weight 248 Kg 546.5 lb

2.06 Maximum WeldingGenerator Operating Angles

Do not exceed operating angles while running or enginedamage will occur.

The operating angle is a maximum of 25 degrees.

2.07 Installing WeldingGenerator

1. Lifting forks.2. Lifting Eye. Use lifting eye or lifting forks to move unit.

If using lifting forks, extend forks beyond opposite sideof unit.

3. Trailer - Install unit on trailer according to trailermanufacturing.

Movement - Do not lift unit from end.

1 2


2.08 LocationA proper installation site should be selected for thewelding generator if the unit is to provide dependableservice and remain relatively maintenance free.

CAUTION: OPERATE IN OPEN, WELL VENTILATEDAREAS, OR IF OPERATED INDOORS, VENTENGINE EXHAUST OUTSIDE THE BUILDING.KEEP ENGINE EXHAUST OUTLET AWAY FROMBUILDING AIR INTAKES.

2.09 Air Flow Clearance

Maintain at least 19.7 inch (500mm) of unrestricted space onall sides of the unit, and keep underside free of obstructions.

Do not place any filtering device over the intake air passages ofthis welding generator. Warranty is void if any type of filteringdevice is used.

The service life and operating efficiency of this unit isreduced when the unit is subjected to high levels of dust,dirt, moisture, and corrosive vapors.

WARNING: SPARKS CAN CAUSE BATTERY GASESTO EXPLODE BATTERY ACID CAN BURN EYESAND SKIN.

• Stop engine before disconnecting or connecting batterycables.

• Always wear a faceshield and proper protective clotingwhen working on battery.

• Do not allow tools to cause sparks when working on abattery.

• Place the engine control switch in the STOP position.• Remove bolts and pull out tray.• Connect the cables• Reinstall battery tray.

WARNING: ENGINE FUEL CAN CAUSE FIRE OREXPLOSION.

• Stop engine before fueling.• Do not fuel while smoking or near sparks or flames.• Do not overfill tank-clean up any spilled fuel.

REMOVE FUEL CAP SLOWLY-FUEL SPRAY MAYCAUSE INJURYFUEL MY BE UNDER PRESSURE.Rotate fuel cap slowly and wait until hissing stopsbefore removing cap. Check all fluids daily. Enginemust be cold and on a level surface. Add fresh fuelstarting engine the first time.


2.10 Generator AuxiliaryPower System

Standard Receptacles

(1) Circuit breakers to protect (2) GFCI receptacles fromoverload.

(2) 120 V 15 A AC Duplex GFCI receptacle. Supplies 60Hz single-phase power at maximum speed (3600 rpm).Maximum output each receptacle is 1.8 kVA/kW.

(3) Circuit breakers to protect (4) 240 V receptacle fromoverload.

(4) 240 V 50 A AC receptacle. Supplies 60 Hz single-phasepower at maximum speed (3600 rpm). Maximum output is8.5 kVA/kW.

(11) Earth ground connection.

(1) 460 V 13 A AC three phase Circuit Breaker connection.Supplies 60 Hz three-phase power at maximum speed (3600rpm). Maximum output is 10 kVA/kW.

To connect load remove the two retaining knobs holding theaccess panel. After opening the panel connect a cable to beused to supply the 460V three phase load to the three phasecircuit breaker mounted to the access panel. Connected the

ground cable to the bolt mounted next to the circuit breaker.Route the cable through the cable clamp (2) and securecable. Re-secure the access panel with the two retainingknobs to the front panel.

2.11 Wiring Optional 230 VoltPlug

The plug can be wired for a 230V, 2-wire load or a115/230V, 3-wire load. See diagram below

White - Neutral terminal.YYY - Load 1 terminal.XXX - Load 2 terminal.Green - Ground terminal.

Select proper insolated and grounded equipment.

1) Auxiliary power receptacles are Neutral bonded toframe.

2) 3-Prong plug for case Grounded equipment3) 2-Prong plug for double insulated equipment.


2.12 Grounding TheGenerator

TO A TRUCK OR TRAILER FRAME1. Generator base.2. Metal vehicle frame.3. Equipment grounding terminal.4. Grounding cable. Use # 10 AGW or larger insulated copper

wire.

NOTE: FOR THE GFCI RECEPTACLES TO PERFORMPROPER PROTECTION THE WELDING GENERATORMUST BE EARTH GROUNDED.

2.13 When Connecting ToHome, Shop, or Farm Wiring

NOTE: THIS UNIT SHOULD NEVER BE USED AS THEMAIN SOURCE OF POWER.

1. Equipment grounding terminal.2. Grounding cable. Use # 10 AGW or larger insulated

copper wire.3. Water meter.4. Metal water pipe5. Driven ground rod.

Typical connection to supply emergency or standby power.

1. Power Company Service Meter.2. Main and Branch Over-current Protection.3. Double-Pole, Double-Throw Transfer Switch. Obtain

and install correct switch. Switch rating must be sameas or greater than the branch over-current protection.

4. Circuit Breaker or Fused Disconnect Switch. Obtainand install correct switch.

5. Extension Cord. Generator Connections. Connectterminals or plug of adequate amperage capacity tocord. Follow all applicable codes and safety practices.Turn off or unplug all equipment connected to generatorbefore starting or stopping engine. When starting orstopping, the engine has low speed which causes lowvoltage and frequency.

6. Load connections.

NOTE: It is the installer's responsibility to follow theapplicable rules from the National Electrical Code(NEC), state, local, and OSHA codes for the installationand use of auxiliary power generators.


Customer-supplied equipment is required if generator is tosupply standby power during emergencies or power outages.

2.14 Auxiliary PowerRequirements

The following section provides some general guidelines for theinstallation and operation of an auxiliary power generator. Notall the guidelines may be applicable to this specific unit.

The auxiliary power supplied from the generator is mostcommonly used in industrial, small business and residentialapplications. For industrial applications, a portable unit canbe moved to the job site to power portable tools, lights,compressors, etc. For small business and residentialapplications, the generator supplies standby power during apower outage.

It is the installer’s responsibility to follow all applicablecodes when installing an auxiliary power generator. It isalso the installer’s responsibility to determine if thegenerator is capable of supplying adequate power for aspecific application. When installing consult qualified localpersonnel and follow all applicable codes for safe and properinstallation.

Before the generator may be used to supply power, theinstaller must first become familiar with and meet all codesapplicable to the installation of an auxiliary generator. It isthe installer's responsibility to follow the applicable rulesfrom the National Electrical Code (NEC), state, local, andOSHA codes for the installation and use of auxiliary powergenerators.

LOAD EVALUATION

Before connecting or operating the auxiliary powergenerator, the installer must determine if the generator iscapable of supplying adequate power for a specificapplication. Load and generator evaluation is essential forsatisfactory generator and equipment operation. See PowerRequirements Table.

TYPES OF LOAD

Load requirements depend on the type of load connected tothe generator. There are two types of loads, resistive andnon-resistive. A resistive load, such as a light bulb, requiresa constant amount of power from the generator. A non-resistive load, such as a portable grinder, requires variableamounts of power from the generator. Because a grinderrequires more power for motor starting and is rarely usedwith a constant, even pressure, the load requirements canchange greater than the operator anticipates.

RUNNING LOAD REQUIREMENTS

The total running load applied the generator is calculated byadding up all the individual loads. Some requirement israted in amperes, others in watts. The requirements for mostequipment are provided on its nameplate.

Example 1: If a drill requires 5 amperes at 115 volts,calculate its running power requirements in watts.

VOLTS x AMPERES = WATTS115V x 5A = 575WTherefor, the individual load applied by the drill is 575watts.

Example 2: If a light bulb is rated at 200 watts, theindividual load applied the light bulb is 200 watts. If three200 watt light bulbs are used with the drill from example 1add the individual loads to calculate total load.(200W + 200W + 200W) + 575W = 1175W

Therefore the total load applied by the three light bulbs anddrill is 1175 watts.

Motor-starting RequirementsStarting amperage requirements are many times the runningamperage of the motor. Starting requirements must bedetermined to assure that the generator is capable of startingthe motor without damaging it. This can be done byexamining the motor nameplate and identifying the codeletter specifying the starting kVA/HP required.

Motor StartCode Leter

KVA/HP

G 6.3


H 7.1J 8.0K 9.0L 10.0M 11.2N 12.5P 14.0

If the kVA/HP requirement, motor horsepower, and voltagerating are known, the starting amperage can be calculated.

Example: Calculate the starting amperage required for a230V, ¼ HP motor with a motor start code of G.

Equation

KVA/HP x HP x 1000= STARTING AMPERAGE

VOLTS

Volts = 230HP = ¼Code G results in kVA/HP = 6.3

6.3 x ¼ x 1000= 6.85A

230

Therefore, starting the motor requires 6.85 amperes.

If a code letter is not present on the motor nameplate,approximate starting amperage is equal to six times runningamperage. This is a reasonable approximation for allapplications where the generator rated amperage is at leasttwice the motor requirement. If the generator-to-motor-sizeratio is less than 2:1 acquire the needed information toproperly determine the motor-starting requirement.

2.15 Simultaneous Weldingand Power((ssiinnggllee oorr tthhrreeee pphhaassee))

WeldCurrent

TotalPower in

Watts

120 voltGFCI

Recept.

240 voltRecept.

8500 max.

460 voltThreephase

270A 1,200 10A 5A 1.5A220A 3,660 15A x 2 15.25A 4.6A170A 4,500 15A x 2 18.75A 5.65A120A 7,000 15A x 2 29A 8.8A70A 8,500 15A x 2 35.4A 10.68A0A 10,000 15A x 2 35.4A 12.5A

CCoommbbiinneedd oouuttppuutt ooff aallll rreecceeppttaacclleess lliimmiitteedd ttoo rraattiinngg ooff tthheeggeenneerraattoorr..

EExxaammppllee:: IIff wweellddiinngg aatt 112200AA aanndd 1155AA iiss ddrraawwnn ffrroomm tthhee112200VV GGFFCCII dduupplleexx rreecceeppttaaccllee,, 1100AA iiss ddrraawwnn ffrroomm tthhee 224400VVrreecceeppttaaccllee,, oonnllyy 33..55AA iiss aavvaaiillaabbllee ooff 446600VV tthhrreeee--pphhaassee..

2.16 Selecting and PreparingWeld Output Cables

1. Weld output cable. Determine total cable length in weldcircuit and maximum welding amperes. Use shortestcables possible. Do not use damaged cables.

2. Welding socket: negative connection.3. Welding socket: positive connection. 2-3-4) Use lugs of

proper amperage capacity and hole size for connectingto work clamp.

4. GTAW torch.5. Insulated electrode holder..6. Wire feeder. Install according to manufacturer's

instruction.7. Work clamp. Install onto work cable.8. Interface conversion kit

TTYYPPIICCAALL PPRROOCCEESSSS CCOONNNNEECCTTIIOONNSS

SEQUENCE OF OPERATIONWARNING: Read end follow all safety precaution beforeproceeding with operation.

SHIELDED METAL ARC WELDING (SMAW) 1) Install and connect unit according to the installationsection. 2) Wear gloves and clothing. 3) Connect work clamp at workplace. 4) Select proper electrode. 5) Place the selector switch in STICK position. 6) Place the OUTPUT CONTACTOR switch in ONposition. 7) If remote amperage control is not used, place theAmperage/Voltage switch in panel position.


8) Rotate the Amperage/Voltage control to desired position. 9) Insert electrode into electrode holder.

GAS TUNGSTEN ARC WELDING (GTAW) Scratch Startonly

1) Install and connect unit according to the Installationsection. 2) Select proper tungsten electrode. 3) Prepare tungsten electrode and insert the torch. 4) Wear gloves and clothing. 5) Connect work clamp to clean, bare metal at work place. 6) Place the process selector switch in Lift Tig position. 7) Place the Amperage/Voltage switch in desired position. 8) Rotate Amperage/Voltage control to desired position. 9) Turn on shielding gas and water supplies as applicable.10) Place the Primary Power switch in ON position.11) Touch electrode to work and lift to start arc.12) Begin welding.

GAS METAL ARC WELDING (GMAW) 1) Install and connect unit. 2) Install and connect wire feed system.3) Wear gloves and clothing.4) Connect work clamp at workplace.5) Place the process selector switch in MIG position. 6) Place the Amperage/Voltage switch in desired position. 7) Rotate Amperage/Voltage control to desired position. 8) Turn on shielding gas supply and set desired flow rate. 9) Place the Primary Power switch in ON position.

10) Begin welding.

SELECTING WELD CABLE SIZES

Weld cable size (AWG) is based on either a 4 volts or lessdrop or a current density of more than 300 circular mils perampere.

19 CIRCUIT TESTING

SECTION 3: TROUBLE SHOOTING GUIDEThe Predator Pro is an asynchronous (brush-less) stylegenerator. The basic theory of this style generator is asfollows:A permanent magnet (rotor) is rotating at a high speedinside a winding wrapped around a laminated steel core(stator). This produces a small voltage at a very lowintensity, 1 to 2 volts at 1 amp in the exciter windings.This low voltage charges the excitation capacitorsconnected in series and directly connected to both ends ofthe exciter windings. This produces a charge-dischargesituation that augments to the point at which it stabilizesitself in proportion to the magnetic force of the rotorwinding wire’s size and length, capacity of the capacitors,and engine speed (3600 rpm) at about 60 times persecond. The Charge-discharge effect produces acollapsing of magnetic field in the laminated steel, thuscreating a current all of its own. This current produced is

proportional to the main winding characteristics, size,lengh, etc.

3.01 There Is No Auxiliary Voltage and/or Welding CurrentIn examining this particular fault it must be remembered that an asynchronous generator with excitation by capacitors has thevaluable characteristic of becoming automatically de-energized while it is functioning ( no longer supplies current ) and of notbecoming self-excited when it is started up if there is a short-circuit whether outside of the generator ( in the user circuit ) orinside it ( in the windings and in the control equipment ).

TROUBLE PPOOSSSSIIBBLLEE CCAAUUSSEE REMEDYThe GFCI is open or when actuated inthe closed position suddenly trips open.

The reset of the G.F.C.I. must be in theclosed position. Check that the usercircuit does not have a phase to earth.

Close the GFCI and disconnect the plugsfrom the current sockets. If the GFCIdoes not remain closed even if the resetis slowly closed, this means that theGFCI is faulty and that it must bereplaced.

The generator is connected to themaximum load, in particular inductionmotors.

When starting, the current plugs shouldnot be connected directly with the load,but with a switch interposed that willallow the set to be started with the loaddisconnected.

Remove the load in the starting phase.If necesasry, disconnected the plugsfrom the current sockets. If generatorstill does not generate welding currentrefer to test section for exciter capacitors& Stator.

The + and - welding cables are in short-circuit through electric contact betweenthem.

The electrode & Work lead areconnected in short circuit condition.

Disconnect electrode & Work leads. Ifgenerator still does not generate weldingcurrent refer to test section for excitercapacitors & Stator.

Excitation Capacitors are shorted. Disconnect the capacitors from thegenerator and from the equipment.Refer to test section for excitationcapacitors.

If necessary, replace the capacitors.

Output welding receptacles loose orshorted.

Check the cable connections to thereceptacles. Check for burnt or loosereceptacle insulation.

Replace the receptacle parts necessary.

Output Welding Rectifier is shorted. With a tester check the diodes andSCR’s in the rectifier as shown introubleshooting guide.

Replace the rectifier or SCR’s assemblyif necessary.

Auxiliary Power

ExcitationCapacitors

MMaaiinn WWeellddWWiinnddiinnggss

20 CIRCUIT TESTING

3.02 The Generator Is De-Energized when Load is connectedPROBABLE CAUSE CONTROLS REMEDIES

There is a short-circuit on the usercircuit.

Check the load for shorts Repair load circuit.

Excessive overload; induction motors(especially 2-pole) connected of higherpower than the Generatorsspecifications.

See that the induction motors are not ofhigher power than the specification ofthe generator.

Reduce load to within the specificationsof the generator.

3.03 Excessive Fall of Voltage When The Load is ConnectedPROBABLE CAUSE CONTROLS REMEDIES

The engine does not maintain thenominal speed.

Check whether the fine current controlis functioning.

Replace or repair Fine Current controlassembly.

Check engine fuel system. Refer to Engine manual for testing fuelsystem.

Check with an ammeter whether theload is greater than the rated load of thegenerator.

Reduce load to within generatorspecifications.

3.04 Single Phase Receptacle Out Of Balance When at IdlingPROBABLE CAUSE CONTROLS REMEDIES

A capacitor of one phase is disconnectedor is no longer working properly.

Check the connections at the terminalsof the capacitors. See capacitor testingin the the Troubleshooting Guide.

Repair the faulty capacitor connections.Replace any capacitor that may be foundto be defective.

3.05 Insufficient Welding CurrentPROBABLE CAUSE CONTROLS REMEDIES

The engine does not obtain maximumspeed.

Check the Fine Current Controlfunction.

Repair or replace the Fine CurrentControl.

Check engine throttle linkage, Fuel andelectrical systems.

Refer to engine manual.

One phase on the capacitors or on therectifiers is disconnected.

Check that all the internal connectionshave a sound electrical connection.

Fix any connections that may haveworked loose.

Faulty winding in stator. Check stator according to Stator sectionin troubleshooting guide.

Replace stator if necessary

Check control PC Board Repair or replace the PC Boardaccording to PC Board troubleshootingsection.

21 CIRCUIT TESTING

3.06 The Battery Runs down Frequently

PROBABLE CAUSE CONTROLS REMEDIESBattery defective: does not maintain theload.

Check for shorted battery cell. Replace battery.

Engine charge circuit defective Test charge circuit according to enginemanual.

22 CIRCUIT TESTING

SECTION 4: CIRCUITTESTING

4.01 Checking the Resistanceof the Stator Windings

Check the generator stator for a short between the auxiliarypower and weld stator by first disconnecting the groundwires from the generator to the ground bolt located on theright side of the generator when facing the front of themachine. Check the resistance from the frame ground toeach stator lead. There should be a open between these twowindings. If you measure a low resistance the stator needsto be replaced.

NOTE: On units with serial numbers older thatT91811A191707C, it will be necessary to disconnectthe cable connected between the work outputterminal and frame ground.

To check the stator for a winding to winding short, itrequires a low resistance-measuring instrument. Such asa Wheatstone Bridge.

First remove the weld and auxiliary stator leads from theirconnections inside the machine.

Second connect your test instrument to the following leadsand measure the resistance.

WELD STATOR

Leads 11 to Lead N2 0.00900 ohm

AUXILIARY POWER STATORLead ¼ to Lead 1 0.24817 ohmLead 1 to Lead 1 0.24877 ohmLead 1 to Lead ¼ 0.24789 ohmLead 2 to Lead ¼ 0.06260 ohm

If the readings you receive are lower than shown above, thiswould indicate a winding to winding short in the stator andthe stator would require replacement.

The resistance value relates to a cold coil at an ambienttemperature of 20 degrees C (68 degrees F) and a generatorwith a nominal voltage of 460V 60 Hz.

WWAARRNNIINNGG:: WWhheenn tthhee mmaacchhiinnee iiss wwoorrkkiinngg,, tthheerree iiss aavvoollttaaggee ooff 444400--550000VVAACC aatt tthhee ccaappaacciittoorr tteerrmmiinnaallss..

4.02 Replacing the StatorTo replace a stator it is recommended that you remove theengine, stator, and armature as one assembly. The assemblycan then be set up on a workbench and the stator can beremoved and reinstalled easier.

To remove the assembly, disconnect and remove the batteryfrom the power supply. Then disconnect all stator leads andpull them through the separation panel.

Unbolt the 4 engine motor mounts and disconnect the enginewire harness. Put a lifting strap around where the generatorand engine are coupled and use a hoist to lift the assemblyfrom the machine.

23 CIRCUIT TESTING

RReemmoovvee tthhee ffaann bbllaaddee ffrroomm tthhee aarrmmaattuurree sshhaafftt aanndd rreemmoovveetthhee 88 ggeenneerraattoorr hhoouussiinngg bboollttss,, ttoo rreemmoovvee tthhee bbeeaarriinngg ccaarrrriieerrssuuppppoorrtt.. TThhee ssttaattoorr sshhoouulldd ccoommee ooffff oovveerr tthhee rroottoorr.. RReevveerrsseetthhee sstteeppss ttoo rreeiinnssttaallll tthhee nneeww ssttaattoorr..

4.03 Excitation CapacitorsDisconnect the excitation capacitors from the circuit beforetesting. With a VOM touch the terminals of the capacitorbeing tested and observe:

a) Whether the needle of the tester shows a temporaypassage of current, which would indicate that thecapacitor is absorbing the load current and is thereforeworking.

b) Whether the needle of the tester goes to the bottom ofthe scale (zero resistance), which would show that thecapacitor is in a short-circuit and must be replaced.

4.04 Output Rectifier andSCR

Diode Check

Both on Positive as well as on Negative diodes, there shouldonly be a one-way current conduction. Connect a VOMacross the diode as shown in the drawing. Use the diodecheck if equipped in your meter or ohms scale X 100. Yourmeter should indicate a low resistance in one direction and ahigh resistance in the other.

If you see a shorted reading in both directions the outputdiode assembly needs to be replaced.

SCR Check

With you VOM , use ohms scale and check the resistancebetween K and G Gate connections. The value should be10 – 100 ohms. Check resistance between Anode andcathode (between K and A Heat sinks). The value shouldbe as a diode.

4.05 Test for PC BoardP95031

Tools needed: DC voltmeter, DC ammeter Dummy load 1,3 OHMS 300 W

0,11 OHMS 8,500 W

A

KG

Heat Sink

K

SCR

24 CIRCUIT TESTING

Pin 1 to Pin 2 19 VAC AC supply to PC Board

Pin 3 to Pin 2 19 VAC AC supply to PC Board

Pin 4 to Pin 6 6 VDC Ref. Volts to output pot.

Pin 5 to Pin 6 .1 to 6 VDC wiper of output control pot.

Pin 7 to pin 6 4 – 6 VDC Arc Force pot. Ref. @ 150amps

Pin 8 to Pin 6 2.6 – 3.8 VDC Arc Force pot. Wiper

Pin 9 to Pin 6 12 – 20 VDC, DC supply on PC Board

Pin 10 to Pin 6 +20 VDC, CV mode 0 VDC CC Mode

Pin 11 Not used

Pin13 to pin 6 Idle switch = AUTO 0 VDC, HIGH 20VDC

Pin 14 to Pin 6 20 VDC in CC or A & B shorted in CVMode

Pin 15 to Pin 6 +12 VDC From Battery for Idle relay

Pin 16 to Pin 6 +12 VDC at Idle, 0 VDC at full speed

Pin 17 to Pin18

.2 ohms Aux Power sense coilresistance

Pin 19 to Pin20

70 VDC, Arc Voltage feedback

Pin 21 to Pin22

55 m VDC, Arc current feedback @ 150amps

Pin 23 to Pin26

20 VAC SCR clock signal

Pin 24 to Pin26


Pin 25 to Pin26


Pin 26 Neutral for weld stator

Pin 27 to Pin30

200 mVDC Gate signal to SCR

Pin 28 to Pin30


Pin 29 to Pin30


Pin 30 Common cathode to SCR’s

4.06 PC Board Adjustmentprocedure

1. START-UP the machine and set it to the maximumRPM.

2. Check the switches and contactors as follows:! CC-CV put in CC position! STICK-TIG put in stick position! AMPERE/VOLT put in PANEL position! HOT START put in OFF position! ARC CONTROL DIAL in OFF position

3. Turn the current dial to the minimum values 15A.4. Connect a dummy load 1,3 OHMS and adjust the

trimmer P10 to read 15A and 20V at the out-put.5. Remove the dummy load.6. Turn the current dial to the maximum values 270A.7. Connect a dummy load 0,11 OHMS and adjust the

trimmer P7 to get 270A and 30,8V.8. Remove the load.9. Turn the current dial to the minimum values 15A.10. Turn the arc force dial to the maximum values.11. Connect a dummy load 0,12 OHMS and check the

output. Correct values must be 13V-105A. Thesevalues can differ from the nominal with a tolerance of+/- 5%.

12. Turn the HOT START to ON position.13. Turn the current dial to 100A.14. Adjust the trimmer P1 while the dummy load is

connected to get a 160-170A output current. Pleaseadjust P1 and connect the load simultaneously.

15. Remove the load.16. Adjust the trimmer P2 to get an output current of 160-

170A in 0,75/1 second time.17. Remove the load.18. Set the HOT START to OFF position.19. Set the STICK-TIG to TIG position.20. Turn the current dial to 100A.21. Simultaneously adjust the trimmer P3 and connect a

load of 0,3 OHMS to get a current rise ramp of 2seconds to reach the value of 100A.

22. Remove the load.23. Set the STICK-TIG selector to STICK position.24. Set the AUTO-HIGH selector to AUTO.25. Turn the current dial to the minimum value 15A.26. Turn the trimmer P4 full counter clockwise.27. Connect the load, engine will go to the maximum rpm

state. After few seconds remove the load and check howlong the engine keeps the maximum rpm, normally 5-7seconds, before to reach the idle status.

28. Set the CC-CV selector to CV position.29. Turn the voltage dial to minimum value 16V.

25 CIRCUIT TESTING

30. Run the engine to the maximum rpm.31. Under unload condition adjust the trimmer P9 to get

16V output voltage.32. Turn the voltage dial t max value 30V.33. Under unload condition adjust the trimmer P6 to get

30V output voltage.

DUMMY LOADYou need a variable resistive load from 0,11 OHMSminimum value to 1,3 OHMS maximum value.We suggest to use 10mm NICHEL CROME WIRE to buildthe dummy load with different taps for the resistive valuesindicated. Total power must be 8500W.

4.07 Calibration procedure foridle adjustment

1. Remove the air cleaner cover and elements to reach theidle screw on the carburetor (see fig. 1)

2. Check the position of the screw on the head of the idlesolenoid (see fig. 2)

3. Remove the canopy4. Turn the trimmer P4 in board P 95031 fully counter

clock wise (see fig. 3)5. Connect a frequency counter to a plug of generating

section6. Set the switch AUTO/HIGH to AUTO position. Set the

switch RUN/STOP to RUN position, then start up themachine. Engine will start at max RPM and go to idleafter a few seconds.

7. Warm up the engine for 5 minutes, after warm upadjust the screw on the carburetor for idle calibration toread a frequency of 51,5 Hz. ± 0,5 Hz (3060 rpm).

4.08 Automatic Idle CircuitThe automatic Idle circuit will hold the engine rpm at lowidle (3000rpm) unit a load is applied through the welding orauxiliary circuits. For the Idle circuit to function theAuto/Idle switch must be in the idle position. With theAuto/Idle switch in the Run position the rpm will be atmaximum rpm (3750 rpm).

The sensing for the weld current comes from the outputcurrent shunt located in series with the (+) Weld output andthe output rectifier heat sink. This sensing signal is appliedto pins 21 and 22 on PC Board (P95031). If you are notwelding there is no output across the shunt (0 VDC appliedto pins 21 and 22). The PC Board circuitry senses this zerovoltage and applies 12 VDC to pin 16 of the PC Board. ThisVoltage is connected to the idle control relay coil. The relayenergizes the normally open contacts to close. 12 VDC(battery voltage) is applied through the relay and to theAuto/Idle switch. With the switch in the Auto position theIdle Solenoid energizes and maintains the engine to idlespeed.

When a load is applied across the welding output terminals avoltage is generated across pins 21 and 22 from the shunt.The PC Board removes the 12 VDC from pin 16 on the PC

26 CIRCUIT TESTING

Board and the idle control relay de-energizes. This removesthe 12 VDC from the Idle Solenoid and the engine speeds upto operating RPM (3750 rpm). When the load is removedthe engine will remain at maximum rpm for approx. 8seconds before returning to idle rpm.

The auxiliary Power sensing circuit uses a currenttransformer. The secondary of the transformer is connectedto pins 17 and 18 of the PC Board. The auxiliary windingsare routes through the center of the Current Transformer.When a load is applied to the auxiliary outlets a current isinduced into the secondary of the transformer. This signal isapplied to pins 17 and 18 of the PC Board. The PC Boardde-energizes the Idle Solenoid the same as explained abovefor the weld circuit.

Automatic Idle Circuit Diagram

4.09 Tests points for PCBoard GS9712/R

PC BOARD TEST

Test Points MeasurementsFrame Gnd. To 15/34 12VDC with ignition switch on.Frame Gnd. To OA 12VDC normal to 0VDC low oil

alert.Frame Gnd. To FCS 12VDC to start and runFrame Gnd. To BCL 12VDC NormalFrame Gnd. to 50 12VDC with start button closed.Frame Gnd. To BC 12VDC at 3800rpmFrame Gnd. To 30 12VDC always

FFoorr SScchheemmaattiicc aanndd PPCC BBooaarrdd llaayyoouutt sseeee aappppeennddiixx AA

4.10 Engine Oil Shut-DownCircuit Tests.

Check oil level before proceeding. Add the recommendedengine oil if necessary.

The Oil-Alert switch is located inside the engine block. Totest located the Yellow and Green wires coming from theengine block under the starter motor. With the engine notrunning disconnect the yellow and green wires from the wireharness. Check for continuity between the yellow and Greenwires with a VOM. If a short circuit is measured (NoResistance) the Oil-Alert Switch is defective and should bereplaced. Contact your local engine Service Center forreplacement procedure.

4.11 Engine Charge CircuitShut-Down Test.

The engine incorporates a 3 Amp charging circuit. To testthe rectifier disconnect the White and two green wires fromthe wire harness going to the rectifier. The rectifier islocated on the side of the engine above the starter. Check forresistance between wires as indicated in the table below.

CHG1(Gr) to CHG2(Gr) InfinityCHG1(Gr) or CHG2(Gr) to DC(W) ContinuityCHG1(Gr) or CHG2(Gr) to Ground InfinityDC(W) to CHG1(Gr) InfinityDC(W) to CHG2(Gr) InfinityDC(W) to Ground InfinityGround to CHG1(Gr) or CHG2(Gr) ContinuityGround to DC (W) Continuity

Should reading not match replace rectifier.To test the charge coil disconnect the two charge coilwindings. Check resistance between wires as indicated intable below.

RReessiissttaannccee 00..2233 –– 00..3311 oohhmmss

Should reading not match replace charge coil.

27 SCHEMATICS

SECTION 5 PARTS LIST

5.01 Stator Parts

28 SCHEMATICS

Item Catalog Number Description1 11-3869 Silencer2 11-3499 Flap3 11-3871 Flange nut M5x16 mm4 11-3533 Washer5 11-3868 Clamp6 11-3721 Oil drain cap7 11-3722 Hose clamp8 11-3720 Oil drain cap9 11-3597 Hook10 11-3873 Engine bulkhead11 11-3795 Engine holder12 11-3017 Engine shock absorber 30x30 mm13 11-3896 Screw M8x25 mm14 11-3851 Nut M8 mm15 11-3659 Engine connection flange16 11-3633 Rotor tie-rod17 11-3872 Washer M10 mm18 11-3664 Stator plate19 11-3870 Screw M3/8’ x 1 ¼ mm20 11-3954 Stator21 11-3660 Stator shock absorber 40x25 mm22 11-3281 Rotor23 11-3308 Flange with bearing seat24 11-3078 Bearing25 11-3307 Tie-rod26 11-3077 Seeger ring27 11-3283 Fan28 11-3284 Spacer

29 SCHEMATICS

5.02 Front Panel

30 SCHEMATICS

Item Catalog Number Description1 11-3119 8A fuse2 11-3118 Fuse holder3 11-3620 Lower aluminium front plate4 11-3316 12V relay5 11-3318 Amperometric transformer6 11-3579 GS9712 electronic panel7 11-3960 Aluminium front plate8 11-3842 1K potentiometer9 11-3227 Battery charge signal lamp10 11-3875 15 ohm ½ W resistor11 11-3876 Oil pressure signal lamp12 11-3956 12K ¼ W resistor13 11-3809 Switch assembly “3 poles”14 11-3957 220 ohm ¼ W resistor15 11-3723 Switch cover16 11-3848 10 K potentiometer17 11-3849 Potentiometer knob assembly18 11-3146 3A circuit breaker19 11-3145 14 poles wire feeder connector20 11-3231 Welding outlet21 11-3232 Male texas plug22 11-3792 Auto / High switch assembly23 11-3152 Start button24 11-3153 Start button cover25 11-3243 Choke knob assembly26 11-3151 Hour meter27 11-3150 Fuel gauge – Monitor fuel level28 11-3810 O – ring29 11-3789 230V 50A 14-50 single phase cover30 11-3046 230V 50A 14-50 single phase outlet31 11-3143 3 poles circuit breaker cover32 11-3779 13A 3 poles circuit breaker33 11-3140 Rubber wire holder34 11-3510 Protection cover35 11-3245 Circuit breaker support36 11-3138 Cable holder37 11-3137 Circuit breaker support38 11-3959 Front panel sheet39 11-3936 Earth clamp40 11-3149 50A circuit breaker41 11-3375 115V 2x15A GFCI 5-15R single phase cover42 11-3050 115V 2x15A GFCI 5-15R single phase outlet43 11-3049 Circuit breaker cover44 11-3048 Ring45 11-3148 20A circuit breaker

31 SCHEMATICS

5.03 Sheet Metal Parts

32 SCHEMATICS

Item Catalog Number Description1 11-3610 Hook gasket2 11-3611 Fuel tank cap gasket3 11-3881 Canopy4 11-3790 Support5 11-3878 Rubber wire holder6 11-3613 Panel7 11-3262 Tie – rod8 11-3331 P95031 electronic panel9 11-3140 Rubber wire holder10 11-3504 Insulator11 11-3675 10 VA Transformer12 11-3676 Transformer support13 11-3577 Rectifier bridge left support14 11-3584 Rectifier bridge15 11-3107 Shunt16 11-3478 Insulator17 11-3104 100 ohm 75 W resistor18 11-3299 Tie – rod19 11-3578 Rectifier bridge right support20 11-3672 Rectifier bridge assembly21 11-3614 3 poles terminal board22 11-3619 Lower conveyor23 11-3286 3x65 µF capacitor24 11-3670 Bridge for capacitor25 11-3329 Tie – rod26 11-3662 Spacer27 11-3674 Reactor28 11-3616 Frame29 11-3677 Fuel tank30 11-3615 Fuel level gauge31 11-3612 Fuel tank cap32 11-3543 12V 44Ah battery33 11-3544 Battery tie – rod34 11-3895 Battery clamp35 11-3257 Battery cover36 11-3949 Positive battery charging clip37 11-3948 Negative battery charging clip38 11-3062 Rear panel

33 SCHEMATICS

5.05 Engine Related Parts

34 SCHEMATICS

Item Catalog Number Description1 11-3901 Screw M5x12 mm2 11-3886 Washer M5 mm3 11-3898 Solenoid protection4 11-3235 Solenoid5 11-3902 Nut M5 mm6 11-3904 Washer M12 mm7 11-3897 Solenoid support8 11-3903 Low nut M12 mm9 11-3899 Throttle plate10 11-3894 Fuse 5A11 11-3118 Fuse holder12 11-3891 Washer M8x18 mm13 11-3892 Washer M6 mm14 11-3893 Screw M6x40 mm15 11-3874 Fuse 25A16 11-3900 Throttle spring

5.06 Common Engine Part NumbersEngine Type GX620K1VXE8 Honda suggested replacement Engine type

GX620K1VXE2 with the followingItem Honda Part Number differences.

Oil Filter 15400-PR3-014 Key type Starting boxAir Filter Element 17210-ZJ1-841 Generator style choke

Fuel Filter 16910-ZE8-015 Generator Style Throttle assemblyFuel Pump 16700-ZJ8-003 Red blower housing

Fuel Solenoid 16200-ZJ1-003Spark Plug 98079-5585V

Starter Solenoid 31204-ZJ1-HO1Starter Motor 31210-ZJ1-811

Voltage Regulator 31710-ZJ1-811

Model number Identification Miscellaneous PartsG General Purpose Engine Catalog Number DescriptionX Over Head Valve NA Battery 12V/340A Style DT50

620 20hp 11-4033 Engine Fuel Warning labelV Tapered PTO Shaft 11-4041 Predator LabelX Oil Alert (shut-down) 11-4037 Oil Drain LabelE 3A Charge Circuit 11-4035 General Warning Label

11-4039 Battery Warning label11-4034 Lift Warning Label

35 SCHEMATICS

SECTION 6: Schematics

36 SCHEMATICS

6.01 System Schematic

37 SCHEMATICS

38 SCHEMATICS

6.02 Idle PC Board 11-3449

39 SCHEMATICS

Date post:	04-Mar-2015
Category:	Documents
Upload:	kdm004xx
View:	857 times
Download:	6 times