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
 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.
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3. Generator Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-4. Controller Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-5. AC Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 4 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 5 − THEORY 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 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6-5. Power Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6-6. Control Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-7. Control Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-8. Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-9. Setting Control Board PC2 For 50 Hz Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-10. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 7 − DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-1. Disassembling/Reassembling Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 9 − PARTS LIST FOR LC199488 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
 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.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Servicing Hazards
The symbols shown below are used throughout this manual STATIC (ESD) can damage PC boards.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Put on grounded wrist strap BEFORE handling
to avoid the hazard. boards or parts.
D Use proper static-proof bags and boxes to
Only qualified persons should test, maintain, and repair this store, move, or ship PC boards.
unit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill. Using a generator indoors CAN KILL

D Do not touch live electrical parts. YOU IN MINUTES.
D Stop engine and remove input power plug from
D Generator exhaust contains carbon monoxide.
receptacle (if applicable) before testing or re-
This is a poison you cannot see or smell.
pairing unit unless the procedure specifically
requires an energized unit. D NEVER use inside a home or garage, EVEN IF
D Insulate yourself from ground by standing or working on dry insu- doors and windows are open.
lating mats big enough to prevent contact with the ground. D Only use OUTSIDE and far away from windows, doors, and
D Do not leave live unit unattended. vents.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing live unit, use the one-hand method. Do not put both FUEL can cause fire or explosion.
hands inside unit. Keep one hand free.
D Stop engine and let it cool off before checking or
SIGNIFICANT DC VOLTAGE exists in inverter power adding fuel.
sources AFTER stopping engine. D Do not add fuel while smoking or if unit is near
D Stop engine on inverter and discharge input capacitors according any sparks or open flames.
to instructions in Troubleshooting Section before touching any D Do not overfill tank; clean up any spilled fuel.
parts.
FIRE OR EXPLOSION hazard.
MOVING PARTS can injure.
D Do not place unit on, over, or near combustible surfaces.
D Keep away from moving parts such as fans,
belts, and rotors. D Do not service unit near flammables.
D Keep away from pinch points such as drive
rolls.
D Have only qualified people remove doors,
BATTERY EXPLOSION can BLIND.
panels, covers, or guards for maintenance D Always wear a face shield, rubber gloves, and
and troubleshooting as necessary. protective clothing when working on a battery.
D Keep hands, hair, loose clothing, and tools D Stop engine before disconnecting or connect-
away from moving parts. ing battery cables.
D Before working on generator, remove spark plugs or injectors D Do not allow tools to cause sparks when working on a battery.
to keep engine from kicking back or starting. D Do not use welder to charge batteries or jump start vehicles.
D Block flywheel so that it will not turn while working on genera- D Observe correct polarity (+ and −) on batteries.
tor components.
D Disconnect negative (−) cable first and connect it last.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.

FLYING METAL or DIRT can injure eyes. BATTERY ACID can BURN SKIN and EYES.
D Wear safety glasses with side shields or face D Do not tip battery.
shield during servicing.
D Replace damaged battery.
D Be careful not to short metal tools, parts, or
D Flush eyes and skin immediately with water.
wires together during testing and servicing.

Belt/Hydraulic Drive Generator TM-4414 Page 1

 STEAM AND HOT COOLANT can burn. H.F. RADIATION can cause interference.
D If possible, check coolant level when engine is D High-frequency (H.F.) can interfere with radio
cold to avoid scalding. navigation, safety services, computers, and
communications equipment.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator. D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D If the engine is warm, checking is needed, and there is no over-
D The user is responsible for having a qualified electrician prompt-
flow tank, follow the next two statements.
ly correct any interference problem resulting from the installa-
D Wear safety glasses and gloves and put a rag over radiator cap. tion.
D Turn cap slightly and let pressure escape slowly before D If notified by the FCC about interference, stop using the equip-
completely removing cap. ment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
ELECTRIC AND MAGNETIC FIELDS (EMF) spark gaps at correct setting, and use grounding and shielding to
can affect Implanted Medical Devices. minimize the possibility of interference.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv- OVERUSE can cause OVERHEATING.
icing areas until consulting their doctor and the
device manufacturer. D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
FALLING EQUIPMENT can injure. D Do not block or filter airflow to unit.

D Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not SHOCK HAZARD from testing.
exceed maximum lift eye weight rating (see
D Stop engine or turn Off welding power source (if
Specifications).
applicable) before making or changing meter
D Use equipment of adequate capacity to lift and lead connections.
support unit.
D Use at least one meter lead that has a self-
D If using lift forks to move unit, be sure forks are long enough to
retaining spring clip such as an alligator clip.
extend beyond opposite side of unit.
D Read instructions for test equipment.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment. READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
HOT PARTS can burn. servicing this unit.
D Do not touch hot engine parts bare-handed. D Consult the Owner’s Manual for welding safety
precautions.
D Allow cooling period before working on
D Use only genuine replacement parts from the manufacturer.
equipment.
D Read and follow all labels and the Technical Manual carefully be-
D To handle hot parts, use proper tools and/or fore installing, operating, or servicing unit. Read the safety in-
wear heavy, insulated welding gloves and formation at the beginning of the manual and in each section.
clothing to prevent burns.
D Reinstall injectors and bleed air from fuel system according to
engine manual.
TILTING OR TIPPING can injure.
D Do not put any body part under unit while lifting.
HYDRAULIC EQUIPMENT can injure
or kill.
D Always use proper equipment (hoists, slings,
chains, blocks, etc.) of adequate capacity to lift D Before working on hydraulic system, turn off
and support components (stator, rotor, engine, and lockout/tagout unit, release pressure, and
etc.) as needed during job. be sure hydraulic pressure cannot be accident-
ally applied.
PINCH POINTS can injure.
D Be careful when working on stator and rotor assemblies. D Do not work on hydraulic system with unit running unless you are a
qualified person and following the manufacturer’s instructions.
D Do not modify or alter hydraulic pump or manufacturer-supplied
EXPLODING PARTS can injure. equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.
D Failed parts can explode or cause other parts to D Keep away from potential pinch points or crush points created by
explode when power is applied to inverters. equipment connected to the hydraulic system.
D Always wear a face shield and long sleeves D Do not work under or around any equipment that is supported only
when servicing inverters. by hydraulic pressure. Properly support equipment by mechanical
means.

TM-4414 Page 2 Belt/Hydraulic Drive Generator

 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. Properly support equipment by mechanical
lockout/tagout unit, release pressure, and be sure
means.
hydraulic pressure cannot be accidentally applied.
D Relieve pressure before disconnecting or con-
necting hydraulic lines.
D Check hydraulic system components and all con-
COMPRESSED AIR can injure or kill.
nections and hoses for damage, leaks, and wear
before operating unit. D Before working on compressed air system,
turn off and lockout/tagout unit, release pres-
D Wear protective equipment such as safety sure, and be sure air pressure cannot be acci-
glasses, leather gloves, heavy shirt and trousers, dentally applied.
high shoes, and a cap when working on hydraulic
system. D Relieve pressure before disconnecting or con-
necting air lines.
D Use a piece of paper or cardboard to search for leaks−−never use
D Check compressed air system components
bare hands. Do not use equipment if leaks are found.
and all connections and hoses for damage,
D HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics leaks, and wear before operating unit.
near sparks or flames; do not smoke near hydraulic fluid. D Do not direct air stream toward self or others.
D Reinstall doors, panels, covers, or guards when servicing is D Wear protective equipment such as safety glasses, hearing pro-
finished and before starting unit. tection, leather gloves, heavy shirt and trousers, high shoes, and
D If ANY fluid is injected into the skin, it must be surgically removed a cap when working on compressed air system.
within a few hours by a doctor familiar with this type of injury or gan- D Use soapy water or an ultrasonic detector to search for
grene may result. leaks−−never use bare hands. Do not use equipment if leaks are
found.
D Reinstall doors, panels, covers, or guards when servicing is
COMPRESSED AIR EQUIPMENT can finished and before starting unit.
injure or kill. D If ANY air is injected into the skin or body seek medical help im-
mediately.
D Before working on compressed air system, turn
off and lockout/tagout unit, release pressure,
and be sure air pressure cannot be accidentally
applied. TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
D Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
D Release air pressure from tools and system be-
structions.
fore servicing, adding or changing attach-
D Do not modify or alter compressor or manufacturer-supplied ments, or opening compressor oil drain or oil fill
equipment. Do not disconnect, disable, or override any safety cap.
equipment in the compressed air system.

1-3. California Proposition 65 Warnings

For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling.
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

1-4. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, restrict access for passers−by or conduct individual risk as-
sessment for welders. All welders should use the following procedures 6. Do not work next to, sit or lean on the welding power source.
in order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
1. Keep cables close together by twisting or taping them, or using a feeder.
cable cover. About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.
Belt/Hydraulic Drive Generator TM-4414 Page 3
 SECTION 2 − DEFINITIONS
2-1. Symbol Definitions

Circuit Breaker
Read Operator’s
Manual A Amperes
V Volts

Alternating Current
Positive Negative Output
(AC)

Protective Earth

h
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. All power regulation components are located in a water-
tight box that is connected by cable to the generator. The generator supplies power when running at the specified
speed with the Power switch on (switch is located on platform). A 3-pole, 30 Amp circuit breaker protects the generator
from overload.

803 233

3-2. Specifications
Drive-Type Output Generator Speed

Single-Phase, 6 kVA/kW, 25 A, 120/240 V,

50/60 Hz
Belt-Drive/Pulley 1.0 Power Factor
100% Duty Cycle 3000 rpm (50 Hz)
Three-Phase 7.5 kVA/kW, 18 A, 3600 rpm (60 Hz)
240 V, 50/60 Hz,
Hydraulic 1.0 Power Factor
100% Duty Cycle

TM-4414 Page 4 Belt/Hydraulic Drive Generator

3-3. Generator Dimensions And Weight

Dimensions

A 20-1/2 in (521 mm)

B 9 in (229 mm)

C 13 in (330 mm) C

A
Weight

110 lb (50 kg)

. A belt-driven model is shown. 803 233

3-4. Controller Dimensions And Weight

Dimensions

A 11-1/2 in (292 mm)

B 9-1/2 in (241 mm)

C 4-1/2 in (114 mm) C

Weight A B

10 lb (5 kg)

803 233

Belt/Hydraulic Drive Generator TM-4414 Page 5

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

300

250
AC VOLTS

200

150

100

50

0
0 5 10 15 20 25 30 35 40 45 50
AC AMPERES

B. 7.5 kVA/kW Three-Phase Output

300

250

200
AC VOLTS

150

100

50

0
0 5 10 15 20 25 30 35 40
AC AMPERES

209 397 / 209 398

TM-4414 Page 6 Belt/Hydraulic Drive Generator

 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

1/2 in. Check Belt Replace

(13 mm) Tension Unreadable
(Belt-Driven Labels.
Models Only)

Every 500 h

Blow Out Inside Of

Service Welding Generator
Generator.
Brushes And Slip Rings. Service
During Heavy Service,
More Often In Dirty Conditions.*
Clean Monthly.

4-2. Overload Protection

! Stop engine.

. When a circuit breaker opens,

it usually indicates a more seri-
ous problem exists. Contact
Factory Authorized Service
Agent.
Open cover to access generator.
1 Circuit Breaker CB1
CB1 protects the generator wind-
ings from overload. If CB1 opens,
generator output stops.
Close covers before operating unit.

803 233

Belt/Hydraulic Drive Generator TM-4414 Page 7

 SECTION 5 − THEORY OF OPERATION
1 Engine/Hydraulic Pump
7
Supplies force to turn revolving
field (rotor). Terminal
AC Or DC Control Circuits Block
2 Revolving Field (Rotor) TE1
Turns at 3000 rpm (50 Hz) or 3600 Generator Output
rpm (60 Hz). The speed and excita-
tion current of the field coils deter- Mechanical Coupling
mine voltages in stator windings. 6
Magnetic Coupling
3 Stator Windings Circuit
Breaker
Supply power to exciter and gener- CB1
ator power circuits.
4 Power Board PC1
Works with PC2 to adjust output by
changing revolving field current af- 1 2 3
ter comparing feedback from PC2 Generator Power
Engine/ Revolving
to generator open-circuit voltage.
Hydraulic Field
Uses current feedback signal for Pump (Rotor) Stator Windings
current limiting circuit to prevent ro-
tor failure from overheating. Exciter
5 Control Board PC2
Works with PC1 to regulate revolv-

Voltage Feedback Signal

ing field current. The PWM (pulse
width modulation) signal originates

Excitation DC Supply
on PC2 and is sent to PC1.
6 Generator Power Circuit
Breaker CB1
Protects the generator windings
from overload.
7 Terminal Block TE1
Provides connection point for cus-
tomer supplied equipment and re-
ceptacles.

Power
Board
PC1

Control
Board
PC2

+12 Volt DC Input Voltage

(Customer-Supplied)

TM-499 Page 8 Belt/Hydraulic Drive Generator

 SECTION 6 − TROUBLESHOOTING
6-1. Troubleshooting Table

. 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.
Do not return the generator unless indicated by the troubleshooting guide and factory authorized service agent.
Do not return the control box. Troubleshoot to the circuit board level.

Trouble Remedy

No generator output at platform AC Be sure generator control switch is turned on at platform.

receptacles.

Check and secure electrical connections at platform, generator, and control box.

Be sure all equipment is turned off when starting unit.

Reset circuit breaker CB1 (see Section 4-2).

Check plug PLG3 connection and/or connections at receptacles RC3 and RC5.

Be sure +12 volts DC input voltage is being supplied to control box.

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 across slip rings (nominal reading is 26
ohms). Replace generator if rotor is open.

Disconnect 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. Replace generator if neces-
sary.

Check power board PC1 and connections, and replace if necessary (see Section 6-4).

Check control board PC2 and connections, and replace if necessary (see Section 6-4).

Low generator output at platform AC Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
receptacles.

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 across slip rings nominal reading is 26
ohms). Replace generator if rotor is open.

Disconnect 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. Replace generator if neces-
sary.

Check power board PC1 and connections, and replace if necessary (see Section 6-4).

Check control board PC2 and connections, and replace if necessary (see Section 6-4).

High generator output at platform AC Verify generator is running at 3600 rpm (60 Hz) or 3000 rpm (50 Hz).
receptacles.

Check slip rings, wiring to brushes, and brush position on slip rings. Install new brushes if necessary. See
Section 6-8.

Check power board PC1 and connections, and replace if necessary (see Section 6-4).

Check control board PC2 and connections, and replace if necessary (see Section 6-4).

Belt/Hydraulic-Drive Generator TM-4414 Page 9

 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.

Disconnect leads 12 and 13 from brushes, and check continuity across slip rings nominal reading is 26
ohms). Replace generator if rotor is open.

Check power board PC1 and connections, and replace if necessary (see Section 6-4).

Check control board PC2 and connections, and replace if necessary (see Section 6-4).

TM-4414 Page 10 Belt/Hydraulic-Drive Generator

Notes

Belt/Hydraulic-Drive Generator TM-4414 Page 11

6-2. Troubleshooting Circuit Diagram For Welding Generator

Resistance Values
a) Tolerance − ±10% unless specified
b) Condition − 70°F (21°C); cold
machine (no warm-up)
c) Wiring Diagram − see Section 8
d) Stop generator before checking
resistance
R1 26 ohms

R2 1 ohm
R3 thru R5 Less than 1 ohm

See Section 6-4

for PC1 data

V6

V7

I2 V8, Waveform B

See Section 6-6

for PC2 data

TM-4414 Page 12 Belt/Hydraulic-Drive Generator

 Test Equipment Needed: Amperage Readings
a) Tolerance − ±5% unless specified
b) Condition − 70°F (21°C); cold
machine (no warm-up); no load
I1 1 amps DC (60 Hz)
No greater than 3.5 amps DC under load
Voltage Readings
I2 1 amps DC (60 Hz)
No greater than 3.5 amps DC under load a) Tolerance − ±10% unless
specified
b) Condition − 70°F (21°C); cold
machine (no warm-up); no load
c) Weld/power rpm unless specified
d) Reference − single arrow:
reference to circuit common
(lead 42); double arrow:
reference to points indicated
e) Wiring Diagram − see Section 8

V2, R2 V1 Rotor: +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
I1 V4 Output (Odd Leg): 245 volts AC
V5 Output: 120 volts AC
V6 Generator Enable: +12 volts DC
when generator is enabled (On); 0
volts DC when not enabled (Off)
V7 Shutdown Signal: +12 volts DC
when shutdown is latched; 0 volts
DC when not latched
V3 V8 PWM Signal: 0 to +15 volts DC
V1, R1

See Section 6-3 for

R3 waveforms A,B

V4, Waveform A V5

R4 R5

210 193-B

Belt/Hydraulic-Drive Generator TM-4414 Page 13

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

gnd

A. Generator Open-Circuit Voltage, No Load, 60 Hz

5 ms 5 V

gnd

B. Pulse Width Modulation (PWM) Signal Between

Power Board PC1 And Control Board PC2

Test Equipment Needed:

TM-4414 Page 14 Belt/Hydraulic-Drive Generator

6-4. Power Board PC1 Testing Information
Be sure plugs are secure before
testing. See Section 6-5 for specific
values during testing.
1 Power Board PC1
2 Receptacle RC31
1
. Receptacle RC31 was pre-
viously labeled RC14.

Test Equipment Needed:

803 236 / Ref. 209 400

6-5. Power Board PC1 Test Point Values

a) Tolerance − ±10% unless

specified
PC1 Voltage Readings
b) Condition − no load; generator
running at 3000 (50 Hz) or 3600
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 Signal: +12 volts DC when shutdown is latched; 0 volts DC when shutdown is not latched

3 +12 volts DC

4 Revolving field (rotor): +25 volts DC at no load with respect to RC31-6; +75 volts DC at full load with
respect to RC31-6

5 Not used

6 Revolving field (rotor): +25 volts DC at no load with respect to RC31-4; +75 volts DC at full load with
respect to RC31-4

7 Circuit common

8 Exciter: 150 volts AC with respect to RC31-9

9 Exciter: 150 volts AC with respect to RC31-8

Belt/Hydraulic-Drive Generator TM-4414 Page 15

6-6. Control Board PC2 Testing Information
Be sure plugs are secure before
2 testing. See Section 6-5 for specific
1 values during testing.
1 Power Board PC2
2 Receptacle RC1

Test Equipment Needed:

803 236 / 207 883-D

6-7. Control Board PC2 Test Point Values

a) Tolerance − ±10% unless

specified
PC2 Voltage Readings
b) Condition − no load; generator
running at 3000 (50 Hz) or 3600
rpm (60 Hz)
c) Reference − to circuit common
(RC1-5) unless noted

Receptacle Pin Value

RC1 1 Voltage Feedback: 240 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 Shutdown Signal: +12 volts DC when shutdown is latched; 0 volts DC when shutdown is not latched

5 Circuit common

6 Revolving field (rotor): +25 volts DC at no load with respect to power board PC1 RC31-4; +75 volts
DC at full load with respect to power board PC1 RC31-4

7 + 12 volts DC

8 Enable Line: +12 volts DC when generator is enabled (On); 0 volts DC when generator is not enabled
(Off)

9 Revolving field (rotor): +25 volts DC at no load with respect to power board PC1 RC31-4; +75 volts
DC at full load with respect to power board PC1 RC31-4

TM-4414 Page 16 Belt/Hydraulic-Drive Generator

6-8. Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings

! Stop generator.
1 Brush Holder Assembly
2 Brushes
3 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.
Inspecting Brushes
Remove end panel. Inspect wires.
2 Remove brush holder assembly.
3
Pull brushes from holders.
Replace brushes if damaged, or if
brush is at or near minimum length.
Acceptable Unacceptable Cleaning Slip Rings
. Brushes must ride
Visually inspect slip rings. Under
completely on slip
normal use, rings turn dark brown.
rings
If slip rings are corroded or surface
is uneven, remove belt to turn shaft
by hand for cleaning.
Clean rings with 220 grit emory pa-
per. Remove as little material as
possible. If rings are deeply pitted
1 and do not clean up, consult gener-
ator factory service.
Reinstall belt, brush holder assem-
bly, and end panel.
1/4 in (6 mm)
Or Less − Replace

7/16 in − 1/2 in
2 (11 − 12 mm) New

Tools Needed:

803 275-A

Belt/Hydraulic-Drive Generator TM-4414 Page 17

6-9. Setting Control Board PC2 For 50 Hz Operation
1 DIP Switch SW1
Switch SW1 is factory set for 60 Hz
operation. Change switch position
if unit is run at 50 Hz.

OR
1 2
OFF

OFF
60 Hz ON ON
60 Hz 50 Hz OFF OFF
50 Hz

R60
R59
A2
U5

C25 Q9 R68
S C13
R53 D G C28 C31 R38
C26 R47 R37 D26 R33
R54 D30 R58
U6 Q12 R67 60HZ 50HZ
SW1 R20
R55 2 R69
OFF

1
S1

U8
R40

R41 C14 R28

R57 R29
C15

R39
D25 D20 D13
C27 D15 R62
R56 R30
C20
+
U4
C12 1

D18 C29
C17
C19 C32
D28
2
3
4

+
R70
C21 R71
5
6
7
8

803 236 / 804 080-A

TM-4414 Page 18 Belt/Hydraulic-Drive Generator

6-10. Checking Unit Output After Servicing
. Also use output waveforms to
check unit output after servic-
ing (see Section 6-3).
Start generator.
1 Platform AC Receptacles (Not
Shown)
2 Terminal Block TE1
Check open-circuit voltage at plat-
form receptacles. With no load
applied, voltage should be 10%
above receptacle 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 TE1 voltages are in-
correct, repeat troubleshooting pro-
cedures in Section 6-1.
! Stop unit.
Allow engine to cool, and complete
2 pre-operational checks in table.

Pre-Operational Checks Test Equipment Needed:

Wipe surfaces clean.

Check labels; replace labels that are unreadable or damaged.

Clean battery terminals. Tighten connections.

Clean outside of entire unit.

803 275

Belt/Hydraulic-Drive Generator TM-4414 Page 19

 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.
1 Rotor
2 Stator Assembly
! Use hoist and lifting strap to care-
fully disassemble/reassemble
generator .
! 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.
Reconnect all leads. Use cable ties to
secure leads away from moving or hot
parts.

Remove brush holder

before disassembling
rotor and stator.

Apply Loctite 242 or Apply SAE 30W oil to

equivalent to screw both ends of studs
before installing. before installing.

803 235

Tools Needed: Torques:

A 95 in lb (10.7 N.m)
B 38 ft lb (52 N.m)
(Belt Tensioner)

TM-4414 Page 20 Belt/Hydraulic-Drive Generator

 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 Serial Or Style Number
Diagram Diagram

Belt/Hydraulic Drive Generator LC199488 thru LE266271 210 193-B See Table 8-1
LE266272 and following 210 193−C

Circuit Board PC1 (Power board) LC199488 and following 203 132-A

Circuit Board PC2 (Control Board) LC199488 and following 207 884-C

Note: Effective with Serial

Number LE226672,
this plug and receptacle are
no longer provided.

210 193-B / 210 193−C

Figure 8-1. Circuit Diagram For Belt/Hydraulic Drive Generator Eff. w/ LC199488 And Following
Belt/Hydraulic-Drive Generator TM-4414 Page 21
 Figure 8-2. Circuit Diagram For Control Board PC2 Eff. w/ Serial No. LC199488 And Following
TM-4414 Page 22 Belt/Hydraulic-Drive Generator
 207 884-C

Belt/Hydraulic-Drive Generator TM-4414 Page 23

 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
 Table 8-1. Lead List Summary For Belt/Hydraulic Drive Generator Eff w/LC199488 And Following
. 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.

Lead Connections Lead Connections

1A STATOR TO CB1 17A PLG1 (4) TO PLG31 (2)
2A STATOR TO CB1 21A CB1 TO TE1 (F)
3A STATOR TO CB1 21B PLG2 (A) TO PLG4 (1)
4A STATOR TO TE1 (C) 21C PLG1 (1) TO RC2 (A)
5A STATOR TO RC4 (3) 21D RC4 (1) TO CB1
5B PLG2 (C) TO PLG4 (3) 22A CB1 TO TE1 (E)
5C RC2 (C) PLG31 (8) 22B PLG2 (B) TO PLG4 (2)
6A STATOR TO RC4 (4) 22C PLG1 (2) TO RC2 (B)
6B PLG2 (D) TO PLG4 (4) 22D RC4 (2) TO CB1
6C RC2 (D) PLG31 (9) 23A CB1 TO TE1 (D)
9A RC5 (B) TO PLG3 (B) (Customer Supplied) 42A RC5 (C) TO PLG3 (C) (Customer Supplied)
9B RC3 (B) PLG1 (8) 42B RC3 (C) TO CONNECTION POINT 1
12A PLG2 (E) TO PLG4 (5) 42C PLG31 (7) TO CONNECTION POINT 1
12B RC2 (E) PLG1 (9) 42D PLG1 (5) TO CONNECTION POINT 1
12C RC4 (5) TO BRUSH 42F END BELL SHROUD TO ENGINE MOUNT
13A PLG2 (F) TO PLG4 (6) 42G CHASSIS TO TE1 (B)
13B RC2 (F) PLG31 (4) 43A RC5 (A) TO PLG3 (A) (Customer Supplied)
13C RC4 (6) TO BRUSH 43B RC3 (A) TO CONNECTION POINT 2
15A PLG1 (6) TO PLG31 (6) 43C PLG31 (3) TO CONNECTION POINT 2
16A PLG1 (3) TO PLG31 (1) 43D PLG1 (7) TO CONNECTION POINT 2

Belt/Hydraulic Drive Generator TM-496 Page 25

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

 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
 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
No. Mkgs. No. Description Quantity

Figure 9-1. Generator Assembly

. . . . . . . . . . . . . . . . . . . 216606 . . Generator Assy, Belt-Drive, Cat (Mitsubishi) (includes) . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 215780 . . Generator Assy, Belt-Drive, Deutz, Ford, Cat (Perkins) (includes) . . . . 1
. . . . . . . . . . . . . . . . . . . 209429 . . Generator Assy, Hydraulic-Drive (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 222229 . . 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, Rtng Int 2.000 Groove Dia X .064 Thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 073301 . . . . Ring, Rtng Ext 1.000 Shaft X .042 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 181143 . . . . Bearing, Ball Rdl Sgl Row .984 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 209426 . . . . Endbell, Gen Belt-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 209427 . . . . Endbell, Gen Hydraulic-Drive Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 221799 . . . . Endbell, Gen Belt−Drive, Turbo (Prior to MB260001R) . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 209426 . . . . Endbell, Gen Belt−Drive, Cat (Turbo) (Eff w/MB260001R) . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 212035 . . . . Rotor, Generator (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 209004 . . . . . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 495154 . . . . . . Bearing, Ball Radial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . +216574 . . . . Stator, Generator Belt-Drive, Cat (Mitsubishi) . . . . . . . . . . . . . . . . . . . . 1

TM-4414 Page 28 Belt/Hydraulic Drive Generator

 Eff w/LC199488 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-1. Generator Assembly (Continued)

... 9 . . . . . . . . . . . +207153 .... Stator, Generator Belt-Drive, Deutz, Ford, Cat (Perkins) . . . . . . . . . . 1
... 9 . . . . . . . . . . . +209430 .... Stator, Generator Hydraulic-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . +221506 .... Stator, Generator Belt-Drive, Turbo (Prior to MB260001R) . . . . . . . . . 1
... 9 . . . . . . . . . . . +248394 .... Stator, Generator Belt-Drive, Cat (Turbo) (Eff w/MB260001R) . . . . . . 1
... 10 . . . . . . . . . . . . . 207911 .... Endbell, Gen Brush Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . 493509 .... Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . 010311 .... Clamp, Nyl .750 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 207442 .... Shroud Assy, Endbell
Belt/Hydraulic-Drive Deutz, Ford, Cat (Perkins) (Turbo) . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 216576 . . . . Shroud Assy, Endbell
Belt-Drive, Cat (Mitsubishi) (LC199488 thru LE266271) . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 220620 . . . . Shroud Assy, Endbell
Belt-Drive, Cat (Mitsubishi) (Eff w/LE266272) . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 220620 . . . . Shroud Assy, Endbell
Belt-Drive, Cat (Turbo) (Eff w/MB260001R) . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . TE1 . . . 172661 . . . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB1 . . . 192565 . . . . Circuit Breaker, Man Reset 3p 30a 250vac . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 230275 . . . . Boot, Circuit Breaker 3 Pole w/Bezel And Hardware . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 210196 . . . . Connector, W/Leads (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . 116045 . . . . . . Housing Plug+Pins, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 010467 . . . . Conn, Clamp Cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 207447 . . . . 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 Elastic Stop Nut . . . . . . . . . . . . . . . . . 4
... 21 ............. 208043 . . . . Stud, Stl .250−20 X 12.875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 22 ............. 209660 . . . . Label, Warning Moving Parts Can Cause Serious Injury . . . . . . . . . . . . 1
... 23 ............. 215793 . . . . Pulley, Drive 1.694 In Bore, 4 Bolt Pat Belt-Drive, Deutz . . . . . . . . . . . 1
... 23 ............. 215794 . . . . Pulley, Drive 1.688 In Bore, 3 Bolt Pat Belt-Drive, Cat/Perkins . . . . . . 1
... 23 ............. 216564 . . . . Pulley, Drive 1.688 In Bore, 4 Bolt Pat
(Belt-Drive Only) Mitsubishi, Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 209120 . . . . Label, Label,Term Mkg Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . *215789 . . Bushing, Stl .938 Id X 1.625 Od X 1.000 Lg (Belt-Drive Only) . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . *215791 . . Pulley, Generator 4.88 Dia (60 Hz Belt-Drive Only)
Deutz, Mitsubishi, Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . . . . . . . . . . . *215792 . . Pulley, Generator 5.63 Dia 50 Hz Belt-Drive, Deutz . . . . . . . . . . . . . . . . . 1
... 26 . . . . . . . . . . . . *215790 . . Pulley, Generator 3.00 Pitch Dia 50 Hz Belt-Drive, Ford . . . . . . . . . . . . . 1
... 27 . . . . . . . . . . . . *208040 . . Tensioner, Belt W/Pully Belt-Drive Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 28 . . . . . . . . . . . . . 221362 . . . . Protector, Lead Mylar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
* Not included in generator assembly.
+ When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Belt/Hydraulic Drive Generator TM-4414 Page 29

 Eff w/LC199488 And Following
3

. Hardware is common and

not available unless listed.

2
5 4
Ref. 803 236

Figure 9-2. Controller Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-2. Controller Assembly

. . . . . . . . . . . . . . . . . . . 215783 . . Control Box, Assy 60 Hz (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 215784 . . Control Box, Assy 50 Hz (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . PC1 . . . 209399 . . . . Circuit Card Assy, Gen Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F1 . . . . 027660 . . . . . . ◊Fuse, Mintr Cer 20. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 210569 . . . . Label, 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 210570 . . . . Label, 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . +207446 . . . . Control Box, Belt/Hydraulic-Driven Generator . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 134201 . . . . Stand−off Support, PC Card .312/.375w/Post&lock .43
Qty 8 Prior to LJ380166R, 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, Mtg PC Card (Eff w/LJ380166R) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................... 210198 . . . . Harness, Wrg Control Box (Not Shown) (includes) . . . . . . . . . . . . . . . . . 1
. . . . . . . RC1, RC14 135134 . . . . . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . RC2 . . . 207351 . . . . . . Conn, Circ 6 Skt Rcpt Pushin Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC3 . . . 207352 . . . . . . Conn, Circ 3 Skt Rcpt Pushin Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................... 202660 . . . . . . Conn, Push 4 Wire 12−16strnd 12−18sld 16−22tinstrnd . . . . . . . . . . . 2
................... 207355 . . . . . . Gasket, Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................... 207356 . . . . . . Gasket (Seal), Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 ............. 215796 . . Harness, Wrg Inter Gen/Control (Belt-Drive Only) (includes) . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . 066104 . . . . Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
................... 188512 . . . . Seal, Wire Univ 6p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . 207350 . . . . Conn, Circ 6 Skt Plug Pushin Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................... 209691 . . . . Seal, Interface Univ 6p/3Row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

TM-4414 Page 30 Belt/Hydraulic Drive Generator

 Eff w/LC199488 And Following
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-2. Controller Assembly

... 5 ............. 210318 . . Harness, Wrg Inter Gen/Control (Hydraulic-Drive Only) (includes) . . . . 1
. . . . . . . . . . PLG4 . . . 066104 . . . . Conn, Rect Univ 084 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
................... 188512 . . . . 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 precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Belt/Hydraulic Drive Generator TM-4414 Page 31

 Miller 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
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2013 Miller Electric Mfg. Co. 2013−01