Footpedal for a Hitachi - Help - Inconsistend Jap diagrams

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I was trying to figure out how to make a footpedal for my hitachi 300DG.At first it didn't seem to be so difficult, the manul has some diagrams.Next I noticed there's a few differences and hickups in the diagrams.This diagram shows it can't be that difficult. However pin 101a doesn't exist but there's a pin 136 available in the welder and 134 has a +12V voltage, but closing the switch will leave the variable resistors without voltage, thus possibility to adjust something.Next image doesn't make things clearer either.This one indeed shows  pin 136, the pins A,B,C,D and E (Ground) are used.But there's a switch and a 2,2k resistor missing. This could be integrated into the plug or the box. There's no switch on the stock box.The next image is consistent with the previous.I've put a variable resistor between pins 134 and 136 with the variable voltage on pin 135. The display didn't change as it should. The remote control box indicates "please confirm accurate current value with the panel meter" so it should change shouldn't it?Anyone?Last edited by ElGuapo; 05-11-2008 at 09:50 AM.
Reply:No electrical technicians over here?????
Reply:Why not contact Hitachi direct and get the answer right from the horse's mouth?
Reply:Hitachi might want to protect their oem accesories and I'm not sure wheather I can reach them or get a decent answer. And it's weekend and an extra holiday over here, so the forum might be quicker than the importer.Lot's of diy guys over here so this might be a better place for such a specific question.
Reply:seems like the map to pearl harbor was better than the wiring diagram to your welder
Reply:A punt in the dark. Have you tried SSC controls? They make some nice quality foot remotes and are pretty open with regards to infomation
Reply:First diagram seems to be faulty. Further the machine needs both variable resistors to be wired and detects the remote control by itself, there's no need for a switch.Once plugged the base current and pulse current (if selected on the welder) can be adjusted between 10 and 300 Amps. The welder atomatically detects which resistor i'm fiddling with.Found this out with some help (or assurance to me from getting things wrong and torching the electrics) from the importer who actually doesn't supply much remote controls with this machine. He had a nice one for me, but it's € 400,-. I think that's a lot, he agreed but couldn't fix me up with a better price.Now I can finish my footpedal. Let see how much mechanical overkill I can put into that....
Reply:Buy a Hobart, Miller< Lincoln or ESAB and you can get some answer.  JohnSMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:Miller, Hobart and Lincoln too expensive in europe for some reason.GF preferred the Hitachi (not because of the nice color)Better lifetime and least malfunctions in a 8/24 production site.Too easy solution.Footpedal sorted anyway without torching the set.
Reply:Finished with the right connectors. Could make some covers for the footpedal though.It's a combined manual panel with a footpedal. With the manual unit I can control min and max pulse amps for the footpedal for accuracy.Connectors are Amphenol mil. spec.