Miller TM-4414K Technical Manual
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Miller TM-4414K Technical Manual

Miller TM-4414K Technical Manual

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TM-4414K
2013−01
Eff. w/LC199488
Description
Belt/Hydraulic-Driven Generator For
Welding Power Sources
Belt-Drive Generator
Hydraulic-Drive Generator
Visit our website at
www.MillerWelds.com

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  • Page 1 TM-4414K 2013−01 Eff. w/LC199488 Description Belt/Hydraulic-Driven Generator For Welding Power Sources Belt-Drive Generator Hydraulic-Drive Generator Visit our website at www.MillerWelds.com...
  • Page 2 INFORMATION ON OLDER UNITS This manual includes operating information for current units. To obtain specific operating information for older models, contact JLG Service at 1−877−554−5438.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ........1-1.

  • Page 5: Section 1 − Safety Precautions For Servicing

    SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage OM-4414L - 2013−01, safety_rtm 2011-10 DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 STEAM AND HOT COOLANT can burn. H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio D If possible, check coolant level when engine is navigation, safety services, computers, and cold to avoid scalding. communications equipment. D Always check coolant level at overflow tank, if D Have only qualified persons familiar with elec- present on unit, instead of radiator.

  • Page 7: California Proposition 65 Warnings

    D Keep away from potential pinch points or crush points created by HYDRAULIC FLUID can injure or kill. equipment connected to the compressed air system. D Do not work under or around any equipment that is supported only D Before working on hydraulic system, turn off and by air pressure.

  • Page 8: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Symbol Definitions Read Operator’s Circuit Breaker Amperes Volts Manual Alternating Current Positive Negative Output (AC) Protective Earth Time Hours Temperature (Ground) Welding Arc Work Connection Voltage Input (Electrode) SECTION 3 − SPECIFICATIONS 3-1. Description This belt or hydraulically-driven generator supplies ac power to the platform to run tools through an ac receptacle, and also operate lights, and cutting and welding equipment.

  • Page 9: Generator Dimensions And Weight

    3-3. Generator Dimensions And Weight Dimensions 20-1/2 in (521 mm) 9 in (229 mm) 13 in (330 mm) Weight 110 lb (50 kg) A belt-driven model is shown. 803 233 3-4. Controller Dimensions And Weight Dimensions 11-1/2 in (292 mm) 9-1/2 in (241 mm) 4-1/2 in (114 mm) Weight...

  • Page 10: Ac Power Curve

    3-5. AC Power Curve The ac power curve shows the power in amperes available from the generator. A. 6 kVA/Kw Single-Phase Output AC AMPERES B. 7.5 kVA/kW Three-Phase Output AC AMPERES 209 397 / 209 398 TM-4414 Page 6 Belt/Hydraulic Drive Generator...

  • Page 11: Section 4 − Maintenance

    SECTION 4 − MAINTENANCE 4-1. Maintenance Schedule Stop engine before maintaining. Service more often if used in severe conditions. To be done by Factory Authorized Service Agent. Every 250 h Check Belt Replace 1/2 in. Tension (13 mm) Unreadable (Belt-Driven Labels.

  • Page 12: Section 5 − Theory Of Operation

    SECTION 5 − THEORY OF OPERATION Engine/Hydraulic Pump Supplies force to turn revolving Terminal field (rotor). AC Or DC Control Circuits Block Revolving Field (Rotor) Generator Output Turns at 3000 rpm (50 Hz) or 3600 rpm (60 Hz). The speed and excita- Mechanical Coupling tion current of the field coils deter- mine voltages in stator windings.

  • Page 13: Section 6 − Troubleshooting

    See Section 6-2 for test points and values and Section 9 and following for parts location. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. To avoid charges that are not covered under warranty, troubleshoot and replace components as described. Warranty requests on equipment that could have been repaired in the field or are misdiagnosed may be denied.
  • Page 14 Trouble Remedy Erratic generator output at platform AC Check and secure electrical connections at platform, generator, and control box. receptacles. Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz). Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary. See Section 6-8.
  • Page 15 Notes Belt/Hydraulic-Drive Generator TM-4414 Page 11...

  • Page 16: Troubleshooting Circuit Diagram For Welding Generator

    6-2. Troubleshooting Circuit Diagram For Welding Generator Resistance Values ± Tolerance − 10% unless specified ° ° Condition − 70 F (21 C); cold machine (no warm-up) Wiring Diagram − see Section 8 Stop generator before checking resistance 26 ohms 1 ohm R3 thru R5 Less than 1 ohm...
  • Page 17 Amperage Readings Test Equipment Needed: ± Tolerance − 5% unless specified ° ° Condition − C); cold machine (no warm-up); no load 1 amps DC (60 Hz) No greater than 3.5 amps DC under load Voltage Readings 1 amps DC (60 Hz) ±...

  • Page 18: Waveforms For Section 6-2

    6-3. Waveforms For Section 6-2 The waveforms represent the output of the generator. When operating properly, the generator waveforms match those shown here. Waveforms shown are for 60 Hertz models; waveforms for 50 Hertz mod- els are similar 5 ms 100 V A.

  • Page 19: Power Board Pc1 Testing Information

    6-4. Power Board PC1 Testing Information Be sure plugs are secure before testing. See Section 6-5 for specific values during testing. Power Board PC1 Receptacle RC31 Receptacle RC31 was pre- viously labeled RC14. Test Equipment Needed: 803 236 / Ref. 209 400 6-5.

  • Page 20: Control Board Pc2 Testing Information

    6-6. Control Board PC2 Testing Information Be sure plugs are secure before testing. See Section 6-5 for specific values during testing. Power Board PC2 Receptacle RC1 Test Equipment Needed: 803 236 / 207 883-D 6-7. Control Board PC2 Test Point Values ±...

  • Page 21: Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings

    6-8. Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings Stop generator. Brush Holder Assembly Brushes Slip Rings Inspecting Brush Position Inspect brush alignment with slip rings. View brush alignment Brush Position On Slip Rings through air vents in stator barrel. Brushes must ride completely on slip rings.

  • Page 22: Setting Control Board Pc2 For 50 Hz Operation

    6-9. Setting Control Board PC2 For 50 Hz Operation DIP Switch SW1 Switch SW1 is factory set for 60 Hz operation. Change switch position if unit is run at 50 Hz. 60 Hz ON 60 Hz 50 Hz OFF 50 Hz 60 HZ 803 236 / 804 080-A TM-4414 Page 18...

  • Page 23: Checking Unit Output After Servicing

    6-10. Checking Unit Output After Servicing Also use output waveforms to check unit output after servic- ing (see Section 6-3). Start generator. Platform AC Receptacles (Not Shown) Terminal Block TE1 Check open-circuit voltage at plat- form receptacles. With no load applied, voltage should be 10% above receptacle rating.

  • Page 24: Section 7 − Disassembly And Reassembly

    SECTION 7 − DISASSEMBLY AND REASSEMBLY 7-1. Disassembling/Reassembling Generator Use Section 6-2 to determine if trouble is in stator, rotor, control box, or combina- tion of these components. Rotor Stator Assembly Use hoist and lifting strap to care- fully disassemble/reassemble generator .

  • Page 25: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside machine case or contact distributor for more information. The following is a list of all diagrams for models covered by this manual. Circuit Wiring Model...
  • Page 26 Figure 8-2. Circuit Diagram For Control Board PC2 Eff. w/ Serial No. LC199488 And Following TM-4414 Page 22 Belt/Hydraulic-Drive Generator...
  • Page 27 207 884-C Belt/Hydraulic-Drive Generator TM-4414 Page 23...
  • Page 28 203 132-A Figure 8-3. Circuit Diagram For Power Board PC1 Eff. w/ Serial No. LC199488 And Following TM-4414 Page 24 Belt/Hydraulic-Drive Generator...
  • Page 29 Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram). Plug PLG31 was previously labeled PLG14. Apply small amount of dielectric grade, nonconductive electric grease (Miller Part No. 146 557) to connectors where factory-applied grease had been present.
  • Page 30 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. TM-4414 Page 26 Belt/Hydraulic Drive Generator...
  • Page 31 TM-4414K 2013−01 Description Belt/Hydraulic-Driven Generator For Welding Power Sources Belt-Drive Generator Hydraulic-Drive Generator Eff w/LC199488 And Following For OM-4414 (209 141) Revisions * Thru L Visit our website at www.MillerWelds.com...

  • Page 32: Section 9 − Parts List For Lc199488 And Following

    SECTION 9 − PARTS LIST FOR LC199488 AND FOLLOWING Hardware is common and not available unless listed. Actual parts may vary from illustration. 803 235−C Figure 9-1. Generator Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-1. Generator Assembly 216606 .
  • Page 33 Eff w/LC199488 And Following Item Dia. Part Mkgs. Description Quantity Figure 9-1. Generator Assembly (Continued) +207153 ....Stator, Generator Belt-Drive, Deutz, Ford, Cat (Perkins) .
  • Page 34 Eff w/LC199488 And Following Hardware is common and not available unless listed. Ref. 803 236 Figure 9-2. Controller Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-2. Controller Assembly 215783 ....Control Box, Assy 60 Hz (includes) .
  • Page 35 Eff w/LC199488 And Following Item Dia. Part Mkgs. Description Quantity Figure 9-2. Controller Assembly 210318 ....Harness, Wrg Inter Gen/Control (Hydraulic-Drive Only) (includes) ..066104 .
  • Page 36 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2013 Miller Electric Mfg. Co. 2013−01...

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