Model TA-10/270 H Service Manual
Contents
1. Item Catalog Number Description 1 11 3375 115V 2x15A GFCI 5 12R single phase cover 2 11 3100 Earth clamp 3 11 3050 115V 2x15A GFCI 5 12R single phase outlet 4 11 3049 Circuit breaker cover 5 11 3048 Ring 6 11 3148 20 circuit breaker 7 11 3232 Plug for welding outlet 8 11 3620 Lower aluminium 9 11 3231 Welding outlet 10 11 3125 F S 100V voltmeter 11 11 3278 59713 electronic panel 12 11 3905 Upper aluminium front plate 13 11 3797 Current selector assembly 14 11 3229 Knob fine adjust 15 11 3622 Eront panel 16 11 3227 Battery charge signal lamp 17 11 3876 Oil pressure signal lamp 18 11 3875 Resistor 15 ohm W 19 11 3449 GS9712 A electronic panel 20 11 3877 Fine adjust throttle unit 21 11 3798 Weld process selector assembly 22 11 3279 F S 400 5A ammeter 23 11 3118 Fuse holder 24 11 3274 25A fuse 25 11 3447 400 5A amperometric transformer 26 11 3243 Choke knob assembly 27 11 3137 Plate for circuit breaker 28 11 3152 Start button 29 11 3153 Start button cover 30 11 3318 Amperometric transformer 31 11 3681 13A 3 poles circuit breaker 32 11 3143 Circuit breaker cover 33 11 3138 Cable holder 34 11 3245 Cover 35 11 3087 Rubber wire holder 36 11 4028 Rubber cap 37 11 3809 Stop Run switch 38 11 3792 Auto High switch 39 11 3723 Switch cover 40 11 3045 Hour meter 41 11 3810 O ring 42 11 3150 Fuel meter 43 11 3149 50 A circuits2. Item Catalog Number Description 1 11 3605 Canopy 2 11 3610 Hook gasket 3 11 3611 Fuel tank cap gasket 4 11 3612 Fuel tank cap 5 11 3613 Panel 6 11 3087 Rubber wire holder 4 11 3262 Tie rod 8 11 3614 3 poles terminal board 9 11 3263 Rubber puffer 10 11 3615 Fuel level gauge 11 11 3269 Fuel prefilter 12 11 3191 Red cover battery charging clip 13 11 3190 Positive battery charging clip 14 11 3193 Blue cover battery charging clip 15 11 3192 Negative battery charging clip 16 11 3257 Battery cover 17 11 3062 18 11 3240 Battery clamp 19 11 3544 Battery tie rod 20 44 Ah 12V battery 21 11 3616 Frame 22 11 3790 Support 23 11 3677 Fuel tank 24 11 3661 Spacer 25 11 3241 3x60 capacitor 26 11 3618 Bridge for capacitor 27 11 3662 Spacer 28 11 3663 Reactor tie rod 29 11 3554 DC reactor 30 11 3432 AC reactor 31 11 3619 Lower conveyor 32 11 3687 Rectifier assembly 33 11 3631 Shunt 36 Catalog Number Description 1 11 3627 RS6 Seeger 2 11 3628 Throttle plate 3 11 3629 4 Nut M6 5 Screw M6x16 mm EXPLODED VIEWS 8 PARTS LIST 37 Catalog Number Description 38 1 Wire assembly 2 Stop nut M 5 3 Washer M 5 4 11 3542 Clamp 5 Washer M 5 6 Nut 5 7
3. Catalog No Description 1 11 3100 Earth clamp 2 11 3050 115V 2x15A GFCI 5 12R single phase outlet 3 11 3049 Circuit breaker cover 4 11 3048 Ring 5 11 3148 20 circuit breaker 6 11 3232 Plug for welding outlet 7 11 3620 Lower aluminium 8 11 3231 Welding outlet 9 11 3125 F S 100V voltmeter 10 11 3279 F S 400 5A ammeter 11 11 3549 Cap 12 11 3796 Upper aluminium front plate 13 11 3801 Plate for earth clamp 14 11 3622 Front panel 15 11 3227 Battery charge signal lamp 16 11 3228 Oil pressure signal lamp 17 11 3229 Knob fine adjust 18 11 3802 Clamping screw 19 11 3789 230V 50A 14 50 single phase cover 20 11 3800 Plate for fine adjust throttle unit 21 11 3797 Current selector assembly 22 11 3798 Weld process selector assembly 23 11 3799 Fine adjust throttle unit 24 11 3807 59910 electronic panel 25 11 3278 GS9713 electronic panel 26 11 3447 400 5A amperometric transformer 27 11 3046 230 50 14 50 single phase outlet 28 11 3375 115V 2x15A GFCI 5 12R single phase cover 29 11 3152 Start button 30 11 3137 Plate for circuit breaker 31 11 3318 Amperometric transformer 32 11 3153 Start button cover 33 11 3243 Choke knob assembly 34 11 3779 13A 3 poles circuit breaker 35 11 3143 Circuit breaker cover 36 11 3138 Cable holder 37 11 3245 38 11 3087 Rubber wire holder 39 11 3510 Cover 40 11 3045 Hour meter 41 11 3809 Stop Run switch assembly 42 11 3792 Auto high switc
4. 5 06 Engine Conversion Parts Catalog Description 1 11 3556 Regulator propane model Beam T50 2 11 3537 Fitting 90 degree 1 8 NPT x 3 16 hose 3 11 3538 Hose Clamp 8 10 mm 4 11 3539 Hose Vacuum 3 16 5 11 3560 Check Valve Vacuum Line 6 11 3561 Hose Vacuum 3 16 7 11 3562 Fitting 90 degree 14 NPT x 3 8 SAE Flare 8 11 3563 Electric Lock Off Filter v4 NPT 9 11 3564 Fitting 90 degree 1 2 NPT x 3 8 SAE Flare 10 11 3565 Hose Fitting High Pressure straight 3 8 11 11 3566 High Pressure Hose SAE 100 R5 5 16 12 11 3567 Bullhead fitting x NPT 13 11 3568 Safety valve Y4 NPT 14 11 3569 Fitting straight 1 2 NPT x 3 8 SAE flare 15 11 3570 Fitting 90 degree 3 8 NPT x 5 8 hose 16 11 3571 Hose Clamp 16 25 mm 17 11 3572 Hose 5 8 dry gas 18 11 3573 Main adjustment hse screw 5 8 x 3 8 19 11 3574 Hose clamp 8 16 mm 20 11 3575 Hose 3 8 dry gas 21 11 3576 Carburetor Propane 22 11 3758 Prime bulb not shown 23 11 3760 Hose Clamp 3 16 not shown EXPLODED VIEWS amp PARTS LIST 55 SECTION 6 SCHEMATICS Revision A HERMALARC A THERMADYNE Company ko vy EXPLODED VIEWS amp PARTS LIST 57 Revision 10 270 115V 230V SINGLE PHASE 460V
5. Circuit breaker 3 pole circuit breaker controls 460V three phase power source 460V Output Access for three phase 460V 60 Hz connections Connect Linel 2 and 3 to the output side of the circuit breaker and the ground to the bolt mounted beside the circuit breaker 2 05 Dimensions Weight Width 530 20 86 Length 1080mm 42 52 A 150 59 B 1050mm 41 34 33mm 1507 D 424 16 69 2 06 Maximum Welding Generator Operating Angles Do not exceed operating angles while running or engine damage will occur 25 25 25 25 The operating angle is a maximum of 25 degrees 2 07 Installing Welding Generator 1 Lifting forks 13 1 Lifting Eye Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 1 Trailer Install unit on trailer according to trailer manufacturing Movement Do not lift unit from end 2 08 Location A proper installation site should be selected for the welding generator if the unit is to provide dependable service and remain relaticely maintenance free CAUTION OPERATE IN OPEN WELL VENTILATED AREAS OR IF OPERATED INDOORS VENT ENGINE EXHAUST OUTSIDE THE BUILDING KEEP ENGINE EXHAUST OUTLET AWAY FROM BUILDING AIR INTAKES INTRODUCTION 2 09 Clearance Maintain at least 19 7 inch 500mm of unrestricted space on all sides of the
6. pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu detravail consultez l artide 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe a d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pas le chalumeau au j amp de plasma dans une zone se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e OC ELECTRIQUE Les chocs ledriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiet et produit de l nergie dedrique haute tension Cette nergie ectrique peut produire des chocs graves voire mortas pour l op rateur et les autres personnes sur le lieu detravail Ne touchez jamais une piece sous tension ou vive porte
7. Air Filter Element 17211 ZJ1 003 17210 ZJ1 841 Fuel Filter 16910 2 8 005 16910 2 8 015 Fuel Pump 16700 ZJ1 003 16700 ZJ8 003 Fuel Solenoid 16200 ZJ1 003 16200 ZJ1 003 Spark Plug 98079 56846 98079 5585V Starter Solenoid 35850 ZJ 1 811 31204 ZJ1 HO1 Starter Motor 31200 ZJ1 004 31210 291 811 Voltage Regulator 31710 291 811 31710 ZJ1 811 kohler engine Oil Filter 12 050 01 Air Filter Pre cleaner 24 083 03 Air Filter Element 47 083 03 Spark Plug 12 132 02 Fuel Filter 11 3269 TAI Part ENGINE IDENTIFICATION Installed in Unit Serial Numbers ending with Unit Serial Numbers ending with 0 GX620K1VXE8 Model number Identification Honda suggested replacement Engine types GX620VXE2 or GX620K 1V XE2 with the following differences General Purpose Engine Key type Starting box Over Head Valve Generator style choke 620 20hp Generator Style Throttle assembly Tapered PTO Shaft Red blower housing Oil Alert shut down 3A Charge Circuit MISCELLANEOUS PARTS Catalog Number Description Battery 12V 340A Style DT50 11 4033 Engine Fuel Warning label 11 4058 Predator Label 11 4037 Oil Drain Label 11 4035 General Warning Label 11 4039 Battery Warning label 11 4034 Lift Warning Label 54
8. Never touch any parts that are electrically live or hot Wear dry gloves and dothing Insulate yourself from the work piece or other parts of the welding drcuit Repair or replace all worn damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to code refer to item 4 in Subsection 1 03 Publications Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual A AND EXPLOSION Fire and explosion can be caused by hot slag sparks or thearc weld Be sure there is no combustible or flammable material the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Provide a fire watch when working in an area wherefire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion 8 Noise can cause permanent hearing loss Arc welding cutting processes can cause noise levels to exceed safe limits You must protect your ears from loud
9. SERVICE TROUBLESHOOTING 4 03 Excitation Capacitors Disconnect the excitation capacitors from the circuit before testing With a VOM touch the terminals of the capacitor being tested and observe a Whether the needle of the tester shows a temporay passage of current which would indicate that the capacitor is absorbing the load current and is therefore working b Whether the needle of the tester goes to the bottom of the scale zero resistance which would show that the capacitor is in a short circuit and must be replaced 4 04 Output Rectifier Select DC Reverse Polarity with the Weld Mode Selector Switch Connect a VOM across the megative and positive output terminals of the welding generator Use the diode check if equipped in your meter or ohms scale X 100 Your meter should indicate a low resistance in one direction and a high resistance in the other 2 INFINITY 24 IF you see a shorted reading in both directions the output fiode assembly needs to be replaced 4 05 Auto Idle Circuit With the Auto Idle Switch in AUTO posistion When current is used from the auxiliary power outlets or when a welding arc is established the 1 current transformer coil applies a AC signal to the TA terminal the PC Board 11 3449 This signal indicates to the board that current is being pulled from the machine and removes the 12VDC output from EM output terminal of the PC Board This 12VDC output is connecte
10. 11 3436 Hook 6 11 3253 11 3437 7 67 11 3254 11 3438 Rightpanel 68 11 3255 11 3439 Left panel 7 69 11 3256 11540 71 11 3258 11 3258 Frontpanel 72 11 3259 11 3259 Upper aluminum front panel 73 11 3260 11 3260 Lower aluminum front panel _74 11 3261 11 3261 Panel 75 11 3262 11 3262 76 11 3263 11 3263 Rubber Bumper 77 11 3264 11 3441 Silencer holder 78 11 3265 11 3265 Silencer 79 11 3266 _ 11 3266 Fueltank 80 11 3267 11 3267 1 1 2 cap fuel tank 81 Gasket fuel tank 82 113269 11 3269 83 11370 11370 Washer 84 113271 11 3271 Fuel drain cap 85 113272 11 3272 Silencer extension 86 113273 11 3273 Oildrain 1 87 113274 11 3274 Fuse25A 88 113118 11 3118 Fusehoder 89 113275 11 3275 Knob weld process 90 ___ 11 3276 11 3276 Weld process selector assembly 91 11 3277 11 3443 Current selector assembly 11 3375 115 1143615 11 3615 Fuel Sending Unit j 111348 Oil Level Dipstick 11136 Stator Bracket j 111 3445 StatorHolder EXPLODED VIEWS amp PARTS LIST 29 5 02 Revision 30 Catalog Number Description 1 11 3592 Fan ring 2 11 3593 3 11 3077 S
11. CUTTING obtainable from the American Welding Society 550 LgeuneRd Miami FL 33126 3 NIOSH SAFETY AND HEALTH ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 4 ANS Standard 7871 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway N ew York NY 10018 5 ANSI Standard 2411 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 6 ANSI Standard 7492 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W Leleune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Standard 70 NATIONAL ELECTRICAL CODE obtainable from the N ational Fire Protection Association Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 GENERAL INFORMATION
12. or stopping the engine has low speed which causes low voltage and frequency 7 Load connections 240 V 120 240 60 Hz 000 120V Three Wire 120 V Service 1 2 5 3 240V 599 y 120V Load 1 1 120V F O O CB on MEE 240V Y 120 240 Volt Y 120V Single Phase Three Wire i 120V Generator Output 5 Connection Ground Customer supplied equipment is required if generator is to supply standby power during emergencies or power outages 2 14 Auxiliary Power Requirements The following section provides some general guidelines for the installation and operation of an auxiliary power generator not all the guidelines may be applicable to this specific unit The auxiliary power supplied form the generator is most commonly used industrial small business and residential applications For industrial applications a portable unit can be moved the job site to power portable tools lights compressors etc For small business and residential applications the generator supplies standby power during a power outage It is the installers responsibility to follow all applicable codes when installing an auxiliary power generator It is also the installers responsibility to determine if the generator is capable of supplying adequate power for a specific application When installing cons
13. 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 position to desired 19 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 less drop or a current density of more than 300 circular mils per ampere INTRODUCTION SECTION 3 TROUBLE SHOOTING GUIDE The Predator is an asynchronous brush less style Charge discharge effect produces a collapsing of magnetic generator The basic theory of this style generator is as field in the laminated steel thus creating a current all of its follows own This current produced is proportional to the main winding characteristics size lengh etc A permanent magnet rotor is rotating at a high speed 9 s inside winding wrapped around a laminated steel stator This produces a small voltage at a very low intensity 1 to 2 volts at 1 amp in the exciter windings This low voltage charges the excitation capacitors connected in series and directly connected to both ends of the exciter windings This produces a charge discharge situation that augments to the point at which it stabilizes i
14. 11 3230 Solenoid support 8 Washer M 8 9 Screw M 8x16 10 Screw 5 25 11 11 3237 Solenoid pin 12 Washer 6 13 Low nut M 12 14 Washer M 12 15 Tie rod 8x60 16 Nut M 8 17 Washer 8 18 Low nut M 6 19 Copper washer M 6 20 11 3235 Solenoid EXPLODED VIEWS 8 PARTS LIST 5 03 Revision D 40 Item Catalog Number Description 1 11 3592 Fan ring 2 11 3593 Fan 3 11 3077 Seeger ring 4 11 3078 Bearing 5 11 3633 Rotor tie rod 6 11 3595 Flange with bearing seat 7 11 3596 Stator 8 11 3597 Hook 9 11 3632 Rotor 10 11 3599 Tie rod 11 11 3873 Engine bulkhead 12 11 3869 Silencer 13 11 3499 Flap 14 11 3721 Oil drain cap 15 11 3722 Hose clamp 16 11 3868 Clamp 17 11 3720 Oil drain pipe 18 11 3533 Washer 19 11 3851 Nut M8 20 11 3017 Engine shock absorber 30x30 mm 21 11 3896 Screw M8x25 mm 22 11 3795 Engine holder 23 11 3871 Flange nut M5x16 24 11 3659 Engine connection flange 25 11 3872 Washer M10 26 11 3870 Screw 3 8 x 1 1 4 27 11 3608 Stator plate 28 11 3660 Stator shock absorber 40x25 mm EXPLODED VIEWS 8 PARTS LIST 20 19 18 13 17 16 15 42 e e 41 40 12 13
15. 11CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Assodation 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Wedding Supply Association 1900 Arch Street Philadelphia PA 19103 14 American Welding Sodety Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 LejeuneRd Miami FL 33126 15 Standard 7882 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont dassifi es comme suit NOTE Toute op ration proc dure ou rensdgnement g n ral sur lequd il importe d insister davantage ou qui contribue l efficacit de fonctionnement du systeme ATTENTION pouvant r sulter l endommagement du mat rid en cas de non r
16. BC 12VDC at 3800rpm Frame Gnd To 30 12VDC always For Schematic and PC Board layout see appendix A 4 06 Engine Oil Shut Down Circuit Tests Check oil level before proceeding Add the recommended engine oil if necessary The Oil Alert switch is located inside the engine block To test located the Yellow and Green wires coming from the engine block under the starter motor With the engine not running disconnect the yellow and green wires from the wire harness Check for continuity between the yellow and Green wires with a VOM a short circuit is measured Resistance the Oil Alert Switch is defective and should be replaced Contact your local engine Service Center for replacement procedure 4 07 Engine Charge Circuit Shut Down Test The engine in the Predator incorporates a 3 Amp charging circuit To test the rectifier disconnect the White and two green wires from the wire harness going to the rectifier The rectifier is located on the side of the engine above the starter Check for resistance between wires as indicated in the table below CHG1 Gr to CHG2 Gr Infinity CHG1 Gr or CHG2 Gr to DC W Continuity Gr or CHG2 Gr to Ground Infinity DC W to CHG1 Gr Infinity DC W to CHG2 Gr Infinity DC W to Ground Infinity Ground to CHG1 Gr or CHG2 Gr Continuity Ground to DC W Continuity Should reading not match replace rectifier 25 Should reading not match repl
17. THREE PHASE HERMAIL Mpermetric tronsforner Pti 204 circuit breaker Pr saa circuit bresker Pt 108 circuit Brecker wozu 902 21 650 18804 gt 2913 Plousos 3n2 1904 e 4181108 2120382222 2129492222 35024 0417021 20404 AIDA 200 n8 ay AQES 06 711 3129192224 aaja 1004 vs at 58 Revision 10 270 lt9wz230v SINGLE PHASE 4604 THREE PHASE WORK ELECTRODE E ur E EXPLODED VIEWS PARTS LIST 59 Revision D IHERMALARC A THERMADYNE Company 60 Revision with Kohler Engine 016659 12499 2140433913 1 10 270 115V 230V SINGLE PHASE Aa 916222 voue 460 THREE PHASE FULL OPTIONALS E 2v 2190109331 2120393522 10025 10044 4012924 S 1 po o 006 022 0170227041 0
18. This unit is designed for use with Shielded Metal Arc Welding SMAW Gas Metal Arc Welding GMAW and GAS Tungsten Arc Welding GTAW processes A digital amperage voltage meter is optional Specifications AC DC Amperage Current Ranges Amperage Range 40 300 40 270 40 70 40 60 Duty Cycle 300 60 270 60 70 135 40 90 AC DC welding current 250 100 250 100 155 240 90 170 Volt Range CV Mode 16 30 200 270 170 260 OCV CC Mode 100 100 260 300 220 270 Auxiliary Power Single Phase 115 2ea Duplex Receptacles 3 5Kva Single Phase 115 240 8 5Kva Three Phase 460 10Kva Engine Make Type HONDA KOHLER Model series GX 620 amp 620K1 COMMAND 20 Number of cylinders 2 2 Displacement 614 614 20 20 Engine Speed 3750 rpm no load 3750 rpm no load Engine speed 2600 rpm Idle 2600 rpm Idle Cooling system Air Air Oil capacity 1 51 0 42 gl 2 1 0 56gl Fuel capacity 37 5 10 gl 3751 1041 Fuel consumption 5 2 Vh 1 4 gl Hr 5 2 VHr Battery 12V 340A 12 340 2 02 Volt Amp Curve DC VOLTS L 1 1 4 1 1 60 120 180 240 270 300 360 DC AMPERES 4 420 Volt ampere curves show the voltage amperage output capabilities of the welding power source Curves of other settings will fall between the curves shown 2 03 Duty Cycle The duty cycle of a welding gen
19. breaker 44 11 3046 230V 50 14 50 single phase outlet 45 11 3789 230V 50A 14 50 single phase cover EXPLODED VIEWS 8 PARTS LIST N 207 N m TO Y Ss Fan en Item Catalog Number Description 1 11 3881 Canopy 2 11 3806 Capacitor support 3 11 3610 Hook gasket 4 11 3611 Fuel tank gasket 5 11 3612 Fuel tank cap 6 11 3613 Panel 4 11 3262 Tie rod 8 11 3614 3 poles terminal board 9 11 3677 Fuel tank 10 11 3615 Fuel level gauge 11 11 3190 Positive battery charging clip 12 11 3880 Rear panel 13 11 3948 Negative battery charging clip 14 11 3257 Battery cover 15 11 3895 Battery clamp 16 11 3544 Battery tie rod 17 44 Ah 12 battery 18 11 3878 Rubber wire holder 19 11 3790 Support 20 11 3616 Frame 21 11 3661 Spacer 22 11 3241 3x60 capacitor 23 11 3618 Bridge for capacitor 24 11 3662 Spacer 25 11 3663 Reactor tie rod 26 11 3554 DC reactor 27 11 3432 reactor 28 11 3087 Rubber wire holder 29 11 3619 Lower conveyor 30 11 3631 Shunt 31 11 3879 Rectifier assembly 32 11 3504 Insulator 33 11 3625 40 250V capacitor EXPLODED VIEWS 8 PARTS LIST 46 11 15 10 11 12 13 13 14 Catalog Number Description 1 11 390
20. noiseto prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual ARC WELDING RAYS Arc Welding Cutting Rays can injure your eyes and burn your skin The arc welding cutting process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable dothing to protect your skin from the arc rays and sparks 7 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 shields Use the shade of lens as recommended in Subsection 1 03 item 4 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 2 ANSI Standard 249 1 SAFETY IN WELDING AND
21. that will allow the set to current sockets If generator still be started with the load j does generate welding disconnected current refer to test section for exciter capacitors amp Stator The and welding cables are The electrode amp Work lead are Disconnect electrode amp Work in short circuit through electric connected in short circuit leads If generator still does contact between them condition generate welding current refer to test section for exciter capacitors amp Stator Excitation Capacitors are Disconnect the capacitors from necessary replace the shorted the generator and the capacitors equipment Refer to test section for excitation capacitors Output welding receptacles Check the cable connections to Replace the receptacle parts loose or shorted the receptacles adjacent necessary insulating are not been burnt or loose Output Welding Rectifier is With a tester check the diodes in Replace the rectifier assembly if shorted the rectifier as shown in necessary troubleshooting guide 20 The winding of the generator or Disconnect the case ground Refer to the Troubleshooting components of the equipment connections and using a VOM Guide for detailed component are shorted to ground check all components for a short testing to ground 3 02 The Generator 15 De Energized when Load is connected PROBABLE CAUSE CONTROLS There is a short ci
22. unit and keep underside free of obstructions Do not place any filtering device over the intake air passages of this welding generator Warranty is void if any type of filtering device is used The service life and operating efficiency of this unit are reduced when the unit is subjected to high levels of dust dirt moisture and corrosive vapors WARNING SPARKS CAN CAUSE BATTERY GASES TO EXPLODE BATTERY ACID CAN BURN EYES AND SKIN e Stop engine before disconnecting or connecting battery cables e Always wear a faceshield and proper protective cloting when working on battery e Do not allow tools to cause sparks when working on a battery e Place the engine control switch in the STOP position e Remove bolts and pull out tray e Connect the cables e Reinstall battery tray STOP WARNING ENGINE FUEL CAN CAUSE FIRE OR EXPLOSION 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 MAY CAUSE INJURYFUEL MY BE UNDER PRESSURE Rotate fuel cap slowly and wait until hissing stops before removing cap Check all fluids daily Engine must be cold and on a level surface Add fresh fuel starting engine the first time 2 10 Generator Auxiliary Power System Standard Receptacles 1 Circuit breakers to protect 11 receptacles from overload 2 240 V 50 A AC receptacle S
23. 1 Screw M5x12 mm 2 11 3886 Washer M5 mm 3 11 3898 Solenoid protection 4 11 3235 Solenoid 5 11 3902 Nut M5 mm 6 11 3904 Washer M12 mm 7 11 3897 Solenoid support 8 11 3903 Low nut M12 mm 9 11 3899 Throttle plate 10 11 3894 Fuse 5A 11 11 3118 Fuse holder 12 11 3891 Washer M8x18 mm 13 11 3892 Washer M6 mm 14 11 3893 Screw M6x40 mm 15 11 3274 Fuse 25A EXPLODED VIEWS amp PARTS LIST 47 5 04 With Kohler Engine Item Catalog No Description 1 11 3592 Fan ring 2 11 3593 3 11 3077 Seeger ring 4 11 3078 Bearing 5 11 3633 Rotor tie rod 6 11 3595 Flange with bearing seat 7 11 3596 Stator 8 11 3597 Hook 9 11 3632 Rotor 10 11 3599 Tie rod 11 11 3873 Engine bulkhead 12 11 3793 Silencer 13 11 3499 Flap 14 11 3608 Stator plate 15 11 3961 Engine bracket 16 11 3721 Oil drain cap 17 11 3722 Hose clamp 18 11 3719 Clamp 20 19 11 3794 Oil drain pipe 20 11 3017 Engine shock absorber 30x30 mm 21 11 3795 Engine bracket 22 11 3660 Stator shock absorber 40x25 mm 23 11 3851 Flange M8 24 11 3659 Engine connection flange 25 11 3872 Washer M10 26 11 3870 Screw 3 8 x1 14 11 3235 Idle Solenoid Not Shown EXPLODED VIEWS amp PARTS LIST 49 tt St gE t Ub 50
24. 2 11 3685 Upper aluminium front plate 13 11 3275 Knob weld process 14 11 3622 Front panel 15 11 3227 Battery charge signal lamp 16 11 3228 Capacitor holder 17 11 3229 Knob fine adjust 18 11 3623 Capacitor holder 19 11 3624 GS9811 electronic panel 20 11 3625 40pF capacitor 21 11 3277 Current selector assembly 22 11 3276 Weld process selector assembly 23 11 3626 Fine adjust throttle unit 24 11 3449 GS9712 A electronic panel 25 11 3278 59713 electronic panel 26 11 3447 400 5A amperometric transformer 27 11 3274 25A fuse 28 11 3118 Fuse holder 29 11 3152 Start button 30 11 3137 Plate for circuit breaker 31 11 3318 Amperometric transformer 32 11 3153 Start button cover 33 11 3243 Choke knob assembly 34 11 3681 13A 3 poles circuit breaker 35 11 3143 Circuit breaker cover 36 11 3138 Cable holder 37 11 3245 Cover 38 11 3087 Rubber wire holder 39 11 3510 Cover 40 11 3045 Hour meter 41 11 3809 Stop Run switch 42 11 3811 Auto High switch 43 11 3723 Switch cover 44 11 3810 O ring 45 11 3150 Fuel meter 46 11 3149 40 A circuits breaker 47 11 3046 230V 50 14 50 single phase outlet 48 11 3789 230V 50A 14 50 single phase cover EXPLODED VIEWS 8 PARTS LIST 49 11 3375 115 2 15 5 12R single phase cover 34 WON WN WWW EXPLODED VIEWS 8 PARTS LIST 35
25. 40 Battery clamp 33 11 3192 11 3192 Negative battery charging clip 34 11 3193 11 3193 Blue cover battery charging clip 35 __ 11 3190 11 3190 Positive battery charging clip 36 11 3191 11 3191 Red cover battery charging clip 37 11 3241 11 3286 3x70 uF capacitors 38 11 3142 11 3142 Bridgeforcapacitors 39 11 3287 11 3287 Plate for capacitors 40 11 3152 11 3152 Start button Start button cover 42 11 3243 11 3243 Chokeknobassembly 43 11 3151 11 3151 Hourmeter 44 11 3150 11510 Fuelmeter 45 11 3046 11 3046 230V 50 14 50 single phase outlet 46 11 3149 11 3149 40A circuit breaker 47 11 3048 11 3048 Ring 48 11 3049 11 3049 Circuit breaker cover j 11 3100 11 3100 Earth clamp j 28 50 113050 11 3050 11157 2 15 GFCI 5 12R single phase outlet tem Catalog Number O SSS SSS BRev Description 1 51 113148 11318 20A circuit breaker 52 113244 113244 230Cover 53 11 2145 113245 1400 3144 0 00 00000 57 11 340 11 3140 Rubber wire holder 58 11 3137 11 3137 Plate for circuit breaker 59 11 3143 11 3143 460V Circuit breaker cover 60 11 3247 11 3247 Lower front panel 61 11 3248 11 3434 Rightframe 62 11 3249 11 3435 _ Leftframe 63 11 3250 11 3250 Reactor support 64 11 3251 11 3251 Battery support 65 11 3252
26. 41 021 wh Anoeronetr Ironsforner 13 20 cwcuit breaker 50A circuit renker pte To HOLY IND SNONGAHINAST 120115 vooy 334 61 EXPLODED VIEWS 8 PARTS LIST APPENDIX A BCL O 2 200940 0 vers 10 poo 970 TIH voor 015 02 404 01 4004 wo 20 a e EN A ws c 91 9212659 1126 D4 CRZ 4 05 4004 1 06 4004 9g 3 03 fiv R1 1ee LES ak 4 5110 R16 10K R28 10kK T HPS 42 Idle control PCBoard 62 fe tom T ram H PERNT ES Na 2 APT 2 tuor J A As s 95508 N x9 ey za UIQ 7924407 HOLAS Idle Control Board Schematic 63 EXPLODED VIEWS 8 PARTS LIST
27. EDES DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Assodation des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA 1172 CODE DE SECURITE POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Assodation des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 ivr amp NWSA BIBLIOGRAPHIE SUR LA SECURITE DU SOUDAGE disponible aupr s de l Assodation Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSF4 1 de l Association m ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Wedding Society 550 LeJeune Rd Miami FL 33126 15 Norme ANSI Z882 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 SECTION 2 TECHNICAL SPECIFICATIONS 2 01 Specifications The Thermal Arc TA 10 270 H 15 a gasoline engine driven DC welding generator with selectable Constant Current CC and Constant Voltage CV output characteristics
28. IHERMAL THERMADYNE Company Model TA 10 270 H PREDATOR AC DC CC CV Welding Generator STICK MIG AUXILIARY POWER Service Manual Manual No 430429 493 GENERAL INFORMATION Table Contents Date 04 01 02 3 Manual GENERAL INFORMATION 4 Date 04 01 02 5 Manual SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as follows NOTE An operation procedure or background information which requires additional emphasis or is hdpful in efficient operation of the system mmm CAUTION A procedure which if not properly followed may cause damageto the equipment WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area 1 02 Important Safety Precautions OPERATION AND MAINTENANCE WELDING EQUIPMENT CAN BE DANGEROUSAND HAZARDOUS TO YOUR HEALTH To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions VM FUMES Gases and fumes produced during the Arc welding cutting proces can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume p
29. L ARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 5 Norme ANS 2411 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupres de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI 7492 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROCEDES DE COUPE ET DE SOUDAGE disponible aupr s de l American National GENERAL INFORMATION 10 Standards Institute 1430 Broadway New York NY 10018 7 Norme 60 de l Assodation Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Sodety 550 N W LejeuneRd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROCEDES ASSOCIES disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de National Fire Protection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC
30. Lead 11 0 00900 ohm 23 AUXILIARY POWER STATOR Lead 4 to Lead 1 0 24817 ohm Lead 1 to Lead 1 0 24877 ohm Lead 1 to Lead 1 4 0 24789 ohm Lead 2 to Lead 1 4 0 06260 ohm If the readings you receive are lower than shown above this would indicate a winding to winding short in the stator and the stator would require replacement The resistance value relates to a cold coil at an ambient temperature of 20 degrees C 68 degrees F and a generator with a nominal voltage of 460V 60 Hz ASYNCHRONOUS GENERATOR WHEATSTONE BRIDGE WARNING When the machine is working there is a voltage of 440 500VAC at the capacitor terminals 4 02 Replacing the Stator To replace a stator it is recommended that you remove the engine stator and armature as one assembly The assembly can then be set up on a workbench and the stator can be removed and reinstalled easier To remove the assembly disconnect and remove the battery from the power supply Them disconnect all stator leads and pull them through the separation panel Unbolt the 4 engine motor mounts and disconnect the engine wire harness Put a lifting strap around where the generator and engine are coupled and use a hoist to lift the assembly from the machine Remove the fan blade from the armature shaft and remove the 8 generator housing bolts to remove the bearing carrier support The stator should come off over the rotor Reverse the steps to reinstall the new stator
31. One phase on the capacitors or Check that all the internal any connections that electrical connection section in troubleshooting guide 21 SERVICE TROUBLESHOOTING 3 06 The Battery Runs down Frequently PROBABLE CAUSE CONTROLS REMEDIES Battery defective does not Check for shorted battery cell Replace battery maintain the load Engine charge circuit defective Test charge circuit according to engine manual 22 SECTION 4 CIRCUIT TESTING 4 01 Checking the Resistance of the Stator Windings Check the generator stator for a short between the auxiliary power and weld stator by selecting the AC weld mode of operation Check the resistance from the frame ground to the work weld output terminal There should be an open between these two windings If you measure a low resistance the stator needs to be replaced NOTE On units with serial number older that T91811A191707C it will be necessary to disconnect the cable connected between the work output terminal and frame ground To check the stator for a winding to winding short it requires a low resistance measuring instrument Such as a Wheatstone Bridge Wheatstone Bridge First remove the weld and auxiliary stator leads from their connections inside the machine Second connect your test instrument to the following leads and measure the resistance WELD STATOR Lead 11 to Lead 11C 0 24560 ohm Lead N2 to Lead 11 0 01618 ohm Lead N2 to
32. Volts 230 1 4 Code G results in kVA HP 6 3 6 85 230 Therefore starting the motor requires 6 85 amperes INTRODUCTION If a code letter is not present the motor nameplate approximate starting amperage is equal to six times running amperage This is a reasonable approximation for all applications where the generator rated amperage is at least twice the motor requirement If the generator to motor size ratio is less than 2 1 acquire the needed information to properly determine the motor starting requirement 2 15 Simultaneous Welding and Power Weld Current max single or three phase 120 volt 240 volt Recept Recept 8500 Total Power in Watts 460 volt Three phase TIPICAL PROCESS CONNECTIONS 3 660 5 65 SEQUENCE OF OPERATION WARNING Read end follow all safety precaution before proceeding with operation 8 500 10 68A 10 000 Combined output of all receptacles limited to rating of the generator Example If welding at 120A and 15A is drawn from the 120V GFCI duplex receptacle 10A is drawn from the 240V receptacle only 3 5A 15 available of 460V three phase 2 16 Selecting and Preparing Weld Output Cables 1 Weld output cable Determine total cable length in weld circuit and maximum welding amperes Use shortest cables possible Do not use damaged cables 1 Welding socket negative connection 1 Welding socket positive connection 2 3 4 Use lug
33. ace charge coil SERVICE TROUBLESHOOTING SECTION 5 PARTS LIST 5 01 Revision A amp IE 06 6 21 02 5 2 26 EXPLODED VIEWS amp PARTS LIST 27 Atv LB Rev Description Rotor 3 11 3216 11 3216 Engine connecting flange 4 113217 11 3217 Flange with bearing seat 5 113218 11 3218 Statortierod 6_ 1132179 11329 Rotortierod 8 11 3077 11 3077 __ Seeger ring 9 113220 11 3220 Fan 10 11 3221 11 3221 11 11 3222 11 3431 Reactor DC 12 11 3223 11 3223 5 13 11 3224 11 3432 Reactor AC 14 11 3225 11 3225 Spacer 15 11 3120 11 3318 Amperometric transformer 16 11 3226 11 3226 GS9712electronicpanel 18 11 3228 11 3228 Signal lamp oil pressure 19 11 3229 11 3229 Knobfineadjust 20 11 3230 11 3230 Fine adjust throttle unit 21 11 3231 11 3231 Weldingoutlet 22 11 3232 11 3232 Plug for welding outlet 22 11 3233 11 3233 6 poles terminal board 24 __ 11 3091 11 3091 8 poles terminal board 25 11 3093 11 3093 1 1 2 wire holder 26 11 3234 11 3433 Rectifier assembly Throttle solenoid 28 11 3236 11 3236 Solenoid support 29 11 3237 11 3237 Solenoid pin 340A 12 battery 31 11 3239 11 3239 Battery tie rod j 32 11 3240 11 32
34. d to the idle solenoid coil and with the idle solenoid re energized the engine governor controls the speed of the engine This engine speed can be set from 2600rpm minimum to 2800rpm maximum by the fine current control on the unit When the current load is removed the unit will stay at high speed for approximately 10 seconds After this time the PC Board will apply 12VDC from EM terminal through the closed posistion on the auto idle switch to the idle solenoid coil The solenoid will energize and lock the engine speed down to idle 2600rpm The auto idle switch in the fast posistion open will bypass the auto control circuit The unit will operate at the speed set by the fine adjust on the front panel continuously Idle Solenoid Fast EM Terminal in PN Board 12VDC to Idle OVDC while welding or using auxiliary power PC BOARD TEST No Load Test Points Load Frame Gnd To TA 0 VDC VAC 100A Frame Gnd To TA 12 VDC idle 0 VDC Measurements Frame Gnd To 15 34 12VDC with ignition switch on To test the charge coil disconnect the two charge coil windings Check resistance between wires as indicated in table below Resistance 0 23 0 31 ohms Frame Gnd OA 12VDC normal to OVDC low oil alert Frame Gnd To FCS 12VDC to start and run Frame Gnd To BCL 12VDC Normal Frame Gnd to 50 12VDC with start button closed Frame Gnd To
35. eeger ring 4 11 3078 Bearing 5 11 3633 Rotor tie rod 6 11 3595 Flange with bearing seat 7 11 3596 Stator 8 11 3597 Hook 9 11 3632 Rotor 10 11 3599 Tie rod 11 11 3657 Engine bulkhead 12 11 3791 Silencer 13 11 3499 Flap 14 11 3603 Clamp 10 15 Flange screw M6x16 mm 16 11 3721 Oil drain cap 17 11 3722 Hose clamp 18 11 3719 Clamp 20 19 11 3720 Oil drain pipe 20 11 3017 Engine shock absorber 30x30 mm 21 11 3795 Engine holder 22 Flange nut M8 23 11 3659 Engine connection flange 24 Washer M10 25 Screw M9x30 mm 26 11 3608 Stator plate 27 11 3660 Stator shock absorber 40 25 mm EXPLODED VIEWS 8 PARTS LIST CO DO N O AN 0 CN QV N NN cR 8 30 31 32 It ji 34 33 32 2 41 1746 45 039 38 37 36 35 A Catalog Number Description 1 11 3100 Earth clamp 2 11 3050 115 2x15A GFCI 5 12R single phase outlet 3 11 3049 Circuit breaker cover 4 11 3048 Ring 5 11 3047 15A circuit breaker 6 11 3232 Plug for welding outlet 7 11 3686 Lower aluminium 8 11 3231 Welding outlet 9 11 3125 F S 100V voltmeter 10 11 3279 F S 400 5A ammeter 11 11 3549 Cap 1
36. erator is the percentage of a ten minute period that a welding generator can be operated at a given output without causing overheating and damaging of the unit This unit is rated at 60 percent duty cycle when operated at 270 amperes The unit can be operated at 270 amperes for six consecutive minutes but it must operate at no load for the remaining four minutes to allow proper cooling if the welding amperes decrease the duty cycle increases If INTRODUCTION the welding amperes are increased beyond rated output the duty cycle will decrease CAUTION CONTINUAL EXCEEDING OF DUTY CYCLE RATINGS CAN CAUSE DAMAGE TO THE WELDING POWER SOURCE 2 04 Front Panel Descriptions Use to select welding current for mode and CV for MIG mode Battery Charge Lamp Should the charging circuit fail the Battery Charging Lamp will turn on and unit will turn off Fine adjustment controls throttle for fine welding control of current CC and voltage CV Rotating this control in a clockwise direction increases the amperage or voltage output The scale surrounding the control represents approximate actual amperage or voltage values Oil Level lamp Should the oil sensor in the engine detect a low oil condition the Oil Level Lamp will turn on and engine will shut off Polarity switch Sets welding polarity for DC Negative DC Positive or AC Serial Number Welding Receptacle Positive Positive output welding connecti
37. espect dela proc dureen question Aku SSEMENT pouvant provoquer des blessures l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dureen question GENERAL INFORMATION 8 1 05 Precautions De Securite Importantes SSEMENT L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez amp suivez tous les avertissements toutes les pr cautions de s curit amp toutes les consignes avant d utiliser le mat rid Composez le 603 298 5711 ou votre distributeur local si vous avez des questions La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant del arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal des diff rents proc d s Vous devez prendre soin lorsque vous coupe ou soudez tout
38. h assembly 43 11 3723 Switch cover 44 11 3150 Fuel meter 45 11 3149 50 circuits breaker 46 11 3810 O ring EXPLODED VIEWS 8 PARTS LIST 51 52 Item Catalog No Description 1 11 3803 2 11 3610 Hook gasket 3 11 3611 Fuel tank cap gasket 4 11 3612 Fuel tank cap 5 11 3804 Panel 6 11 3087 Rubber wire holder 7 11 3262 Tie rod 8 11 3614 3 poles terminal board 9 11 3263 Rubber puffer 10 11 3615 Fuel level gauge 11 11 3269 Fuel prefilter 12 11 3806 Capacitor holder 13 11 3949 Positive battery charging clip 14 11 3806 Capacitor holder 15 11 3948 Negative battery charging clip 16 11 3257 Battery cover 17 11 3805 18 11 3895 Battery clamp 19 11 3544 Battery tie rod 20 11 3543 44 Ah 12V battery 21 11 3616 Frame 22 11 3677 Fuel tank 23 11 3661 Spacer 24 11 3241 3x60 uF capacitor 25 11 3618 Bridge for capacitor 26 11 3662 Spacer 27 11 3663 Reactor tie rod 28 11 3554 DC reactor 29 11 3432 AC reactor 30 11 3619 Lower conveyor 31 11 3879 Rectifier assembly 32 11 3631 Shunt 33 11 3790 Rubber wire holder support 34 11 3504 Insulator 35 11 3625 40uF capacitor EXPLODED VIEWS 8 PARTS LIST 53 5 05 Common Engine Part Numbers Honda Engines GX620 A B C Spec GX 620 K1 D Spec Oil Filter 15400 PR3 004 15400 PR3 014
39. lume Usean air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the arc welding cutting depend on the kind of metal being used coatings on the metal and the different processes You must be very careful GENERAL INFORMATION 6 when cutting or welding any metals which may contain one or more of thefollowing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsedion 1 03 Publications in this manual Use special equipment such as water or down draft welding cutting tables to capture fumes and gases Do not use the welding torch in an area where combustible or explosive gases or materials are located Phosgene toxic gas is generated from the vapors of chlorinated solvents and deansers Remove all sources of these vapors SHOCK Electric Shock can injure or kill The arc welding process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the operator or others in the workplace
40. n gas can be eliminated asthe hydrogen gas may detonate BRUIT GENERAL INFORMATION Le bruit peut provoquer une perte permanente de Les proc d s soudage de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d dez vous prot ger les oreilles contre les bruits forts afin d amp viter une perte permanente Pour prot ger votre ouie contre les bruits forts portez des tampons protecteurs des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu detravail faut mesurer les niveaux sonores afin d assurer que les d ibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester lebruit consultez l artide 1 page 5 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 2 Norme ANSI 7491 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t A m ricaine de Soudage American Welding Society 550 N W LgeuneRd Miami FL 33126 3 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE
41. on for CC Constant Current and CV Constant Voltage Amperage meter optional Volt Meter optional Welding Receptacle Negative Negative output welding connection for CC Constant Current STICK an TIG POAT un RO 9 fears ee J 9 11 10 115 20 Circuit Breakers Push to reset Controls 115V power source for the 115V duplex receptacles 230 115V Single Phase Receptacle Supplies 60 Hz single phase power at weld power speed Engine RUN STOP Switch Place in the RUN position to operate generator Use the START BUTTON to start engine To shut off engine place switch in STOP position Start Button Used to start the engine Set the RUN START switch to RUN push START Button to start engine When engine starts release button Choke for easier starting Hour meter Monitors Time in hours when the engine is on Engine Auto high switch When in Auto the unit will idle until a load is applied In High position the engine will operate above idle RPM Fuel Gauge Monitors fuel level Earth Connection used to earth ground the generator fot auxiliary power 230 115V Circuit Breakers Push to reset Controls 230 115V power source for the 230 115V receptacle 115V Duplex Receptacles Ground fault interrupt protection receptacle for 115V 60Hz power source
42. r une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm RAYONS D ARC DE PLASMA Les rayons provenant de de plasma peuvent blesser vos yeux et br ler votre peau Le proc d a l arc de plasma produit une lumi re infrarouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un ran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les incdles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Respectez le teint de lentille recommand dans le article 4 page 5 Hydrogen gas may be present under aluminum workpieces during the cutting process when being cut underwater or using a water table DO NOT aluminum underwater or on a water table unless the hydroge
43. rcuit on the Check the load for shorts ELLEN load circuit user circuit Excessive overload induction See that the induction motors are Reduce load to within the motors especially 2 poll not of higher power than the specifications of the generator connected of higher power than specification of the generator the Generators specifications 3 03 Excessive Fall of Voltage When The Load is Connected The engine does not maintain the Check whether the fine current Replace or repair Fine Current nominal speed control is functioning control assembly Refer to Engine manual for testing fuel system LM with an ammeter whether Reduce load to within generator the load is greater than the rated specifications load of the generator 3 04 Single Phase Receptacle Out Of Balance When at ldling PROBABLE CAUSE CONTROLS REMEDIES A capacitor of one phase is Check the connections at the Repair the faulty gt capacitor disconnected or is no longer terminals of the capacitors See connections Replace any working properly capacitor testing in the the capacitor that may be found to Troubleshooting Guide be defective 3 05 Insufficient Welding Current PROBABLE CAUSE CONTROLS REMEDIES The engine does not obtain Check the Fine Current Control Repair or replace the Fine maximum speed function Current Control Check 22 throttle linkage PE engine manual 2 2 electrical systems
44. s of proper amperage capacity and hole size for connecting to work clamp 1 GTAW torch 1 Insulated electrode holder 1 Wire feeder Install according to manufacturer s instruction 1 Work clamp Install onto work cable 1 Interface conversion kit SHIELDED METAL ARC WELDING SMAW 1 Install and connect unit according to the installation section 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 ON position 7 If remote amperage control is not used place the Amperage 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 Start only 1 Install and connect unit according to the Installation section 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 WELDING GMAW
45. t 2 12 Grounding The Generator TO A TRUCK OR TRAILER FRAME 1 Generator base 2 Metal vehicle frame 3 Equipment grounding terminal 4 Grounding cable Use 10 AGW or larger insulated copper wire INTRODUCTION FOR PERFORM PROPER PROTECTION THE WELDING GENERATOR MUST BE EARTH GROUNDED NOTE RECEPTACLES TO 2 13 When Connecting To Home Shop or Farm Wiring NOTE THIS UNIT SHOULD NEVER BE USED AS THE MAIN SOURCE OF POWER 1 Equipment grounding terminal 1 Grounding cable Use 10 AGW or lager insulated copper wire 1 Water meter 1 Metal water pipe 1 Driven ground rod Te 4 dL i Ale E d 211 Fi Typical connection to supply emergency or standby power 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 same as or greater than the branch over current protection 4 Circuit Breaker or Fused Disconnect Switch Obtain and install correct switch 5 Extension Cord Select as shown in the Extension Cord Selection Chart 6 Generator Connections Connect terminals or plug of adequate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or stopping engine When starting
46. ted in amperes others in watts The requirements for most equipment are provided on its nameplate Example 1 a drill requires 5 amperes at 115 volts calculate its running power requirements in watts VOLTS x AMPERES WATTS 115V x 5A 575W Therefor the individual load applied by the drill is 575 watts 17 6 3 x 1 4 x 1000 Example 2 If a light bulb is rated at 200 watts the individual load applied the light bulb is 200 watts If three 200 watt light bulbs are used with the drill from example 1 add the individual loads to calculate total load 200W 200W 200W 575W 1175W Therefore the total load applied by the three light bulbs and drill is 1175 watts Motor starting Requirements Starting amperage requirements are many times the running amperage of the motor Starting requirements must be determined to assure that the generator is capable of starting the motor without damaging it This can be done by examining the motor nameplate and identifying the code letter specifying the starting kVA HP required Motor Start KVA HP Code Leter 2 lt 14 0 If the requirement motor horsepower voltage rating are known the starting amperage can be calculated Example Calculate the starting amperage required for a 230V HP motor with a motor start code of Equation KVA HP x HP x 1000 STARTING AMPERAGE VOLTS
47. tself proportion to the magnetic force of the rotor winding wire s size and length capacity of the capacitors and engine speed 3600 rpm at about 60 times per second The Excitation Capacitors Auxiliary Power Weld Windings 3 01 There 15 No Auxiliary Voltage and or Welding Current In examining this particular fault it must be remembered that a asynchronous generator with excitation by capacitors has the valuable characteristic of becoming automatically de energized while it is functioning no longer supplies current and of not becoming self excited when it is started up if there is a short circuit whether outside of the generator in the user circuit or inside it in the windings and in the control equipment The GFCI is open or when The reset of the G F C I must be Close the GFCI and disconnect actuated in the closed position it in the closed position Check that the plugs from the current suddenly spring open the user circuit does not have a sockets If the does phase to earth remain closed even if the reset is slowly closed this means that the GFCI is faulty and that it must replaced The generator is connected to When starting the current plugs Remove the load in the starting the maximum load in particular should not be connected directly phase if necesasry induction motors with the load but with a switch disconnected the plugs from the interposed
48. ult qualified local personnel and follow all applicable codes for safe and proper installation Before the generator may be used to supply power the installer must first become familiar with and meet all codes applicable the installation of auxiliary generator It is the installer s responsibility to follow the applicable rules from the National Electrical Code NEC state local and OSHA codes for the installation and use of auxiliary power generators LOAD EVALUATION Before connecting or operating the auxiliary power generator the installer must determine if the generator in capable of supplying adequate power for a specific application Load and generator evaluation is essential for satisfactory generator and equipment operation See Power Requirements Table TYPES OF LOAD Load requirements depend on the type of load connected to the generator There are two types of loads resistive and non resistive A resistive load such as a light bulb requires a constant amount of power from the generator A non resistive load such as a portable grinder requires variable amounts of power from the generator Because a grinder requires more power for motor starting and is rarely used with a constant even pressure the load requirements can change greater than the operator anticipates RUNNING LOAD REQUIREMENTS The total running load applied the generator is calculated by adding up all the individual loads Some requirement is ra
49. upplies 60 Hz single phase power at maximum speed 3600 rpm Maximum output is 8 5 KVA KW 11 120 V 15 A AC Duplex GFCI receptacle Supplies 60 Hz single phase power at maximum speed 3600 rpm Maximum output each receptacle is 1 8 KVA KW 10 Circuit breakers to protect 2 240 V receptacle from overload 9 Earth ground connection i O 7 460 V 13 A AC three phase Circuit Breaker connection Supplies 60 Hz three phase power at maximum speed 3600 rpm Maximum output is 10 To connect load remove the two retaining knobs holding the access panel After opening the panel connect a cable to be used to supply the 460V three phase load to the three phase circuit 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 and secure cable Re secure the access panel with the two retaining knobs to the front panel 2 11 Wiring Optional 230 Volt Plug The plug can be wired for a 230V 2 wire load or a 115 230V 3 wire load See diagram below White Neutral terminal YYY Load 1 terminal XXX Load 2 terminal Green Ground terminal 15 230V BACK PART Select proper insolating and grounded equipment 1 Auxiliary power receptacles are Neutral bonded to frame 2 3 Prong plug for case Grounded equipment 3 2 Prong plug for double insulated equipmen
50. z des gants et des v tements secs Isolez vous de pi ce de travail ou des autres parties du drcuit desoudage R pare ou remplacez toute pi ce us ou endommag e Prenez des soins particuliers lorsque la zone de travail est humide ou moite Monte et maintenez le mat riel conform ment au Code ledrique national des Etats Unis Voir la page5 article 9 D branchez l alimentation dedrique avant tout travail d entretien ou de r paration Lise et respectez toutes les consignes du Manuel de consignes A DIE ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du metal des tincelles des scories chaudes pouvant mettre le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible deretirer dela zone detravail Procurez une bonne a ration de toutes les fum es inflammables ou explosives Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou su
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