Miller TM-4414K Technical Manual Download Page 1

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Visit our website at

www.MillerWelds.com

Description

Belt/Hydraulic-Driven Generator For

Welding Power Sources

TM-4414K

2013

−

Belt-Drive Generator

Hydraulic-Drive Generator

Eff. w/LC199488

Summary of Contents for TM-4414K

Page 1: ...Visit our website at www MillerWelds com Description Belt Hydraulic Driven Generator For Welding Power Sources TM 4414K 2013 01 Belt Drive Generator Hydraulic Drive Generator Eff w LC199488...

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: ...RY OF OPERATION 8 SECTION 6 TROUBLESHOOTING 9 6 1 Troubleshooting Table 9 6 2 Troubleshooting Circuit Diagram For Welding Generator 12 6 3 Waveforms For Section 6 2 14 6 4 Power Board PC1 Testing Info...

Page 4: ......

Page 5: ...according to instructions in Troubleshooting Section before touching any parts MOVING PARTS can injure D Keep away from moving parts such as fans belts and rotors D Keep away from pinch points such a...

Page 6: ...vigation safety services computers and communicationsequipment D Have only qualified persons familiar with elec tronic equipment perform this installation D The user is responsible for having a qualif...

Page 7: ...ound D Reinstall doors panels covers or guards when servicing is finished and before starting unit D If ANY air is injected into the skin or body seek medical help im mediately TRAPPED AIR PRESSURE AN...

Page 8: ...c receptacle and also operate lights and cutting and welding equipment All power regulation components are located in a water tight box that is connected by cable to the generator The generator suppli...

Page 9: ...s And Weight Dimensions 803 233 A B C A belt driven model is shown A 20 1 2 in 521 mm B 9 in 229 mm C 13 in 330 mm Weight 110 lb 50 kg 3 4 Controller Dimensions And Weight Dimensions 803 233 C B A A 1...

Page 10: ...he ac power curve shows the power in amperes available from the generator A 6 kVA Kw Single Phase Output B 7 5 kVA kW Three Phase Output 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 45 50 AC AMPE...

Page 11: ...ls Every 500 h Blow Out Inside Of Generator During Heavy Service Clean Monthly Service Welding Generator Brushes And Slip Rings Service More Often In Dirty Conditions Stop engine When a circuit breake...

Page 12: ...circuit to prevent ro tor failure from overheating 5 Control Board PC2 Works with PC1 to regulate revolv ing field current The PWM pulse width modulation signal originates on PC2 and is sent to PC1 6...

Page 13: ...onnect stator weld leads 1 2 and 3 from circuit breaker CB1 and check continuity between leads Replace generator if necessary Disconnect plug PLG4 and check continuity between exciter leads 5 and 6 Re...

Page 14: ...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 Disconnect leads 12 and 13 from brushes and check continuity acr...

Page 15: ...TM 4414 Page 11 Belt Hydraulic Drive Generator Notes...

Page 16: ...or See Section 6 6 for PC2 data V7 I2 V8 Waveform B V6 See Section 6 4 for PC1 data Resistance Values a Tolerance 10 unless specified b Condition 70 F 21 C cold machine no warm up c Wiring Diagram see...

Page 17: ...otor 25 volts DC at no load 20 75 volts DC at full load 10 V2 Exciter 150 volts AC V3 Voltage Feedback 240 volts AC V4 Output Odd Leg 245 volts AC V5 Output 120 volts AC V6 Generator Enable 12 volts D...

Page 18: ...uit Voltage No Load 60 Hz 5 ms 5 V B Pulse Width Modulation PWM Signal Between Power Board PC1 And Control Board PC2 gnd gnd The waveforms represent the output of the generator When operating properly...

Page 19: ...rpm 60 Hz c Reference to circuit common RC31 7 unless noted Receptacle Pin Value RC31 1 Pulse Width Modulation PWM Signal 0 to 15 volts DC at no load voltage increases with genera tor load 2 Shutdown...

Page 20: ...40 volts AC with respect to RC1 2 2 Voltage Feedback 240 volts AC with respect to RC1 1 3 Pulse Width Modulation PWM Signal 0 to 15 volts DC at no load voltage increases with genera tor load 4 Shutdow...

Page 21: ...holders Replace brushes if damaged or if brush is at or near minimum length Cleaning Slip Rings Visually inspect slip rings Under normal use rings turn dark brown If slip rings are corroded or surfac...

Page 22: ...ration Change switch position if unit is run at 50 Hz SW1 OFF 2 1 R68 3 2 7 6 8 5 4 1 R56 C20 R57 C21 D20 R41 C26 R55 D18 R47 R54 R53 U6 D26 R39 C14 R28 C19 S1 D25 C17 C13 C12 R30 C27 D13 D15 D30 R67...

Page 23: ...ceptacle rating If output voltage is low or not pres ent at platform receptacles check voltages at generator terminal block TE1 see Section 6 2 If TE1 voltages are correct check wiring to platform If...

Page 24: ...r Do not damage rotor or stator windings during this procedure Mark electrical leads and remove brush holder assembly before dis assembling unit Reassemble generator parts using torque values in table...

Page 25: ...s covered by this manual Model Serial Or Style Number Circuit Diagram Wiring Diagram Belt Hydraulic Drive Generator LC199488 thru LE266271 LE266272 and following 210 193 B 210 193 C See Table 8 1 Circ...

Page 26: ...TM 4414 Page 22 Belt Hydraulic Drive Generator Figure 8 2 Circuit Diagram For Control Board PC2 Eff w Serial No LC199488 And Following...

Page 27: ...TM 4414 Page 23 Belt Hydraulic Drive Generator 207 884 C...

Page 28: ...TM 4414 Page 24 Belt Hydraulic Drive Generator 203 132 A Figure 8 3 Circuit Diagram For Power Board PC1 Eff w Serial No LC199488 And Following...

Page 29: ...31 8 6A STATOR TO RC4 4 6B PLG2 D TO PLG4 4 6C RC2 D PLG31 9 9A RC5 B TO PLG3 B Customer Supplied 9B RC3 B PLG1 8 12A PLG2 E TO PLG4 5 12B RC2 E PLG1 9 12C RC4 5 TO BRUSH 13A PLG2 F TO PLG4 6 13B RC2...

Page 30: ...TM 4414 Page 26 Belt Hydraulic Drive Generator Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 31: ...ollowing For OM 4414 209 141 Revisions Thru L Description Belt Hydraulic DrivenGenerator For Welding Power Sources TM 4414K 2013 01 Belt Drive Generator Hydraulic Drive Generator Visit our website at...

Page 32: ...9 Generator Assy Belt Drive Turbo includes Prior to MB260001R 1 249888 Generator Assy Belt Drive Cat Turbo includes Eff w MB260001R 1 1 026206 Key Stl 250 X 250 X 1 750 Belt Drive Only 1 2 207323 Ring...

Page 33: ...Panel End Shroud 1 19 220618 Panel End Shroud Belt Drive Cat Mitsubishi Eff w LE266272 1 19 248395 Panel End Shroud Belt Drive Cat Turbo Eff w MB260001R 1 20 604318 Nut 250 20 50hex 39h Stl Pld Elast...

Page 34: ...J380166R Qty 5 Eff w LJ380166R 070026 Stand off No 6 32 X 437 Lg 250 Hex Al Fem Eff w LJ380166R 3 4 PC2 207882 Circuit Card Assy Control 1 207441 Panel Mtg PC Card Prior to LJ380166R 1 241282 Panel Mt...

Page 35: ...12 Seal Wire Univ 6p S 3row 1 PLG2 207350 Conn Circ 6 Skt Plug Pushin Cable 1 209691 Seal Interface Univ 6p 3Row 1 Recommended Spare Parts When ordering a component originally displaying a precautiona...

Page 36: ...er Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA Canada FAX 920 735 4134 Interna...

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