Instruction/ maintenance manual of the product TM-499C Miller Electric
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Processes Description Stick (SMAW ) W elding Engine Driven Welding Generator TM-499C August 2004 Eff. w/Serial Number LA124002 (Kohler) Eff. w/Serial Number LB086216 (Honda) Visit our website at www.
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SER VICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 1 1 − DISASSEMBL Y AND REASSEMBL Y 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Disassembly Of Unit 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TM-499 Page 1 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1-1. Symbol Usage OM-499H, safety_rtm 8/03 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message.
TM-499 Page 2 STEAM AND HOT COOLANT can burn. D If possible, check coolant level when engine is cold to avoid scalding. D Always check coolant level at overflow tank, if present on unit, instead of radiator . D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
TM-499 Page 3 SECTION 2 − DEFINITIONS 2-1. Symbol Definitions Engine Choke Read Operator’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (.
TM-499 Page 4 3-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) Depth 31-1/4 in (793 mm) B Y Do not exceed tilt angles or engine could be damaged or unit could tip A 31-1/4 in (793 mm) B be damaged or unit could tip.
TM-499 Page 5 3-4. Fuel Consumption (Honda-Powered Units) 802 122 Continuous Welding 3-5. Duty Cycle 802 093 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit and void warranty .
TM-499 Page 6 3-6. Generator Power Curves 198 570 The generator power curves show the ac power available in amperes at the receptacles. A. 60 Hz Model B.
TM-499 Page 7 3-7. V olt-Ampere Curves 198 570 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator .
TM-499 Page 8 SECTION 4 − INST ALLA TION 4-1. Installing W elding Generator install1 10/00* − 802 524-A / Ref. 151 556 / 158 936-A / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 .
TM-499 Page 9 4-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device as stated in electrical codes. 2 3 800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.
TM-499 Page 10 4-5. Engine Prestart Checks (Honda-Powered Units) 802 094-A Full Full Gasoline 1/2 in (13 mm) 1 Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low .
TM-499 Page 1 1 4-7. Connecting T o W eld Output T erminals 196 914 / 495 178 1 Positive (+) W eld Output T erminal 2 Negative ( − ) W eld Output T erminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative ( − ) terminal and electrode holder to Positive (+) terminal.
TM-499 Page 12 SECTION 5 − OPERA TING THE WELDING GENERA T OR 5-1. Controls (Kohler-Powered Units) 802 51 1-A / 802 051 1 / 495 178 6 7 60 Hz . Weld and generator power output stops i f generator overheats or engine speed is too low . 1 Engine Switch Us e switch to open ignition circuit, and to stop engine.
TM-499 Page 13 5-2. Controls (Honda-Powered Units) (See Section 5-3 ) 802 094-A / 802 095 / 495 187 Recoil-Start Electric-Start 60 Hz 50 Hz 1 3 6 2 1 4 5 7.
TM-499 Page 14 5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2 ) . Weld and generator power output stops i f generator overheats or engine speed is too low . 1 Engine Switch On models with recoil-start, use switch to open ignition circuit, and to stop engine.
TM-499 Page 15 SECTION 6 − OPERA TING AUXILIAR Y EQUIPMENT The welding generator provides power while welding and with the Current control in any position. However , under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations.
TM-499 Page 16 6-2. Optional Generator Power Panels Ref. ST-802 124 / H-495 290 / H-495 283 / 495 277 Generator Power Panel 495 315 (USA) Generator Power Panel 495 278 (Canada − CSA) Generator Power.
TM-499 Page 17 6-3. Generator Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. NOTE T otal power from generator NOT to exceed 5500 W a.
TM-499 Page 18 6-4. Wiring Instructions For Optional 120/240 V olt T wistlock Plug (NEMA L14-30P) plug3-1 1/99 − 802 527 1 Plug Wired For 120/240 V , 3-Wire Load When wired for 120 V loads, each du- plex receptacle shares a load with one half of the 240 V receptacle.
TM-499 Page 19 7-2. Routine Maintenance Recycle engine fluids. Y Stop engine before maintaining. . Se e Engine Manual and Maintenance Label. Ser- vice more often if used in severe conditions. * T o be done by Factory Authorized Service Agent. 8 h 20 h Wipe up spills.
TM-499 Page 20 7-3. Overload Protection (Honda-Powered Units) 1 Ignition Circuit Breaker (Electric-Start Models Only) The circuit breaker protects the en- gine battery charging circuit. A short circuit or a battery connected in reverse polarity will trip the circuit breaker .
TM-499 Page 21 7-5. Adjusting Engine Speed (Honda-Powered Units) 802 097-A After tuning engine, check engine speeds. See table for proper no load speeds. If necessary , adjust speeds as follows: Start engine and run until warm. W eld/Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run (60 Hz) position.
TM-499 Page 22 1 Engine Supplies force to turn revolving fields. 2 Revolving Field (Rotor) T urns at 3700 rpm maximum (60 Hz ) for weld and power . The speed and excitation current of the field coils determine voltages in stator windings. 3 Stator Windings Supply power to exciter , generator power , and weld circuits.
TM-499 Page 23 9 Main Rectifier SR2 Changes ac weld current to dc. 10 Suppressor VR1/R2 Protects SR2 from overload. 1 1 Stabilizer L1 Smooths weld output current. 12 Shunt Provides weld current feedback to control board PC1. 13 HF Filter Board PC2 Protects unit from high frequency .
TM-499 Page 24 SECTION 9 − EXPLANA TION OF ELECTRICAL P ARTS elect_parts 7/04 9-1. Safety Precautions − Read Before Using This Guide Y W ARNING: ELECTRIC SHOCK can kill. D Disconnect input power or stop engine before servicing. D Do not touch live electrical parts.
TM-499 Page 25 P ART NAME CIRCUIT SYMBOL PICTURE FUNCTION CLAMP A spring-loaded connection device. A good example would be the “work clamp” used to connect the weld cable from a power source to the workpiece that will be welded. CONT ACTOR A heavy duty relay .
TM-499 Page 26 P ART NAME CIRCUIT SYMBOL PICTURE FUNCTION IGBT A device that is used as an “electronic switch”. When a signal is applied to the gate (G), current is allowed to flow from the emitter (E) to the collector (C). This device is typically used in “Inverter” designed welding machines to control the welding output.
TM-499 Page 27 P ART NAME CIRCUIT SYMBOL PICTURE FUNCTION MOT OR A device that converts electrical energy into mechanical energy . T ypically used to feed wire in a MIG welding system, or pump coolant in a recirculating liquid-cooling system.
TM-499 Page 28 P ART NAME CIRCUIT SYMBOL PICTURE FUNCTION SCR A Silicon Controlled Rectifier (SCR) is an electrical device with three connections, anode, cathode, and gate. It will allow current to flow in only one direction and will only do so after receiving a signal on the gate lead.
TM-499 Page 29 P ART NAME CIRCUIT SYMBOL PICTURE FUNCTION PRESSURE SWITCH A change in the pressure of a gas or liquid will actuate this switch. OPENS ON INCREASE CLOSES ON INCREASE S1 S1 TEMPERA TURE SWITCH T ypically used to protect engines, this switch is actuated by heat.
TM-499 Page 30 P ART NAME CIRCUIT SYMBOL PICTURE FUNCTION TRANSFORMER A device that changes AC voltage from one magnitude to another . T ypically used to reduce high primary voltages to lower welding voltages. T1 T1 T1 IRON CORE AIR CORE FERRITE CORE TRIAC An electronic AC switch.
TM-499 Page 31 SECTION 10 − TROUBLESHOOTING 10-1. T roubleshooting T ables A. Welding . See Section 10-2 for test points and values and Section 13 and following for parts location. T rouble Remedy No weld output. Check weld connections. Disconnect equipment from receptacles when starting unit.
TM-499 Page 32 T rouble Remedy High weld output. Check Current Control R1 setting. Check engine speed, and adjust if necessary (see Section 7-4 or 7-5). Check resistance and connections of suppressor VR1/R2. R2 is 1000 ohms ± 5%. Replace VR1/R2 if necessary .
TM-499 Page 33 T rouble Remedy Disconnect leads 3 and 4 from brushes, and check continuity across slip rings. Replace rotor if necessary . Disconnect stator exciter leads (black) from integrated rectifier SR1, and check continuity between exciter leads.
TM-499 Page 34 T rouble Remedy Engine stopped during normal operation. Check fuel level (see Section 4-4 or 4-5). Open fuel valve (see Section 4- 4 o r 4-5). Close fuel valve before moving unit or carburetor may flood and make starting dif ficult. Check oil level (see Section 4-4 or 4-5).
TM-499 Page 35 Notes W o r k l i k e a P r o ! Pros wel d and cut safel y . Read t he safety rules at the beginni ng of this m anual..
TM-499 Page 36 10-2. T roubleshooting Circuit Diagram For Welding Generator (Use With Section 10-3) V6, A, B See Section 10-4 for waveforms A,B,C,D See also Section 10-5 for PC1 data V5 V4 V3, R5 V8 V.
TM-499 Page 37 197 857-E.
TM-499 Page 38 10-3. T est Points And V alues (Use With Section 10-2 ) V oltage Readings a) T olerance − ± 10% unless specified b) Condition − 70 ° F (21 ° C); cold machine (no warm-up); no loa.
TM-499 Page 39 10-4. W aveforms For Section 10-2 T est Equipment Needed: 5 ms 50 V A. DC/CC Open-Circuit V oltage, No Load, 60 Hz 5 ms 20 V B. 25 V olts DC, 185 Amperes (Resistive Load), 60 Hz gnd gnd W aveforms shown are for 60 Hertz models; waveforms for 50 Hertz models are similar.
TM-499 Page 40 10-5. Control Board PC1 T esting Information 802 524 / 198 221-A Be sure plugs are secure before testing. See Section 10-6 for specific values during testing. 1 Receptacle RC5 2 Receptacle RC4 3 LED1 LED1 lights when board is energized.
TM-499 Page 41 10-6. Control Board PC1 T est Point V alues PC1 V oltage Readings a) T olerance − ± 10% unless specified b) Condition − no load; throttle lever in 60 Hz position c) Reference − t.
TM-499 Page 42 10-7. Replacing Brushes And Cleaning Slip Rings ST-802 524 / ST -801 842 Y Stop engine. 1 Generator End Panel 2 Brush Assembly 3 Brush Holder 4 Brushes Remove end panel. Remove brush assembly . Pull brushes from holders. Replace brushes if damaged, or if brush is a t or near minimum length.
TM-499 Page 43 10-8. Checking Unit Output After Servicing ST-802 524 Start engine. Move throttle control lever to 60 Hz position. 1 W eld Output T erminals Check open-circuit voltage across weld output terminals. There should be 68 volts dc present (see Section 10-2 ).
TM-499 Page 44 SECTION 1 1 − DISASSEMBL Y AND REASSEMBL Y 1 1-1. Disassembly Of Unit 802 524 Use Section 10-2 to determine if trouble is in stator , rotor , engine or combination of these components. Remove cover . Mark and discon- nect stator leads.
TM-499 Page 45 1 1-2. Removing Rotor And Reassembling Generator 802 524 / 802 509 Y Do not damage rotor or sta- to r windings during this pro- cedure. T o remove rotor: 1 Rotor Removal T ool (Customer Supplied) 2 Screw , 7/16-14 x 1-1/4 (Customer Supplied) Remove rotor thru-bolt.
TM-499 Page 46 SECTION 12 − 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.
TM-499 Page 47 197 857-E Figure 12-2. Circuit Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler) Or LA347885 And Following (Honda) (1 Of 2).
TM-499 Page 48 197 857-E Figure 12-3. Circuit Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler) Or LA347885 And Following (Honda) (2 Of 2).
TM-499 Page 49 197 858-C Figure 12-4. Wiring Diagram For Welding Generator Eff. w/ Serial No. LA124002 And Following (Kohler) Or LA347885 And Following (Honda).
TM-499 Page 50 201 026-A Apply small amount of conductive electric com- pound (Part No. 603 978) to terminals where factory-applied compound had been present.
TM-499 Page 51 201 026-A Apply small amount of conductive electric com- pound (Part No. 603 978) to terminals where factory-applied compound had been present.
TM-499 Page 52 SC-198 222 Figure 12-7. Circuit Diagram For Control Board PC1 Eff. w/ Serial No. LA124002 And Following (Kohler) Or LA033425 And Following (Honda).
Processes Description Stick (SMAW) W elding Engine Driven Welding Generator TM-499C August 2004 Eff w/LA124002 Thru LB1 1 1747 (Kohler Only) For OM-499 (197 850) Revisions * Thru B.
TM-499 Page 54 SECTION 13 − P ARTS LIST FOR LA124002 THRU LB1 1 1747 (KOHLER ONL Y) 802 509 . Hardware is common and not available unless listed. 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 Figure 13-1.
Eff w/LA124002 Thru LB1 1 1747 (Kohler Only) TM-499 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quantity 1 +495 247 TOP , control box (specify color) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eff w/LA124002 Thru LB1 1 1747 (Kohler Only) TM-499 Page 56 . Hardware is common and not available unless listed. 196 921 Generator Power Panel 495 315 Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia) 8 9 10 11 13 12 12 14 14 1 23 5 6 4 Generator Power Panel 196 914 (CSA) 7 Figure 13-2.
Processes Description Stick (SMAW) W elding Engine Driven Welding Generator TM-499C August 2004 Eff w/LB1 1 1748 Thru LC061260 (Kohler) Eff w/LB086216 Thru LC061260 (Honda) For OM-499 (197 850) Revisi.
TM-499 Page 58 SECTION 14 − P ARTS LIST FOR LB1 1 1748 THRU LC061260 (KOHLER) AND LB086216 THRU LC061260 (HONDA) 802 509-A . Hardware is common and not available unless listed. 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 49 Figure 14-1.
Eff w/LB1 1 1748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda) TM-499 Page 59 Description Part No. Dia. Mkgs. Item No. Figure 14-1. Main Assembly Quantity 1 +495 247 TOP , control box (specify color) 1 . . . . . . . . . . . . . . . . . . . .
Eff w/LB1 1 1748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda) TM-499 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 14-1. Main Assembly (Continued) Quantity 41 1T 172 661 BLOCK, terminal 1 . . . . . . . . . . . . . . . . . . . . . .
Eff w/LB1 1 1748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda) TM-499 Page 61 . Hardware is common and not available unless listed. 196 921 1 23 5 6 7 4 Generator Power Panel 495 315 (USA) G.
Eff w/LB1 1 1748 Thru LC061260 (Kohler) / LB086216 Thru LC061260 (Honda) TM-499 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 14-2. Generator Power Panels (Figure 14-1, Item 39) Quantity Generator Power Panel 196 914 (CSA) 1 CB1, CB2 495 182 Circuit Breaker , 25A 2 .
Processes Description Stick (SMAW) W elding Engine Driven Welding Generator TM-499C August 2004 Eff w/LC061261 Thru LC552236 (Kohler & Honda) For OM-499 (197 850) Revisions D Thru F.
TM-499 Page 64 SECTION 15 − P ARTS LIST FOR LC061261 THRU LC552236 (KOHLER & HONDA) 802 509-A . Hardware is common and not available unless listed. 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 50 Figure 15-1.
Eff w/LC061261 Thru LC552236 (Kohler & Honda) TM-499 Page 65 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly Quantity 1 +495 247 TOP , control box (specify color) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eff w/LC061261 Thru LC552236 (Kohler & Honda) TM-499 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 15-1. Main Assembly (Continued) Quantity 40 495 236 BASE, control box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eff w/LC061261 Thru LC552236 (Kohler & Honda) TM-499 Page 67 . Hardware is common and not available unless listed. Generator Power Panel 495 315 (USA) Generator Power Panel 495 219 (USA) Generator.
Eff w/LC061261 Thru LC552236 (Kohler & Honda) TM-499 Page 68 Description Part No. Dia. Mkgs. Item No. Figure 15-2. Generator Power Panels (Figure 15-1, Item 39) Quantity Generator Power Panel 495 218 (USA) 1 495 220 P ANEL, generator power assembly 1 .
Processes Description Stick (SMAW) W elding Engine Driven Welding Generator TM-499C August 2004 Eff w/LC552237 And Following (Kohler & Honda) For OM-499 (197 850) Revisions G And H.
TM-499 Page 70 SECTION 16 − P ARTS LIST FOR LC552237 AND FOLLOWING 802 509-A . Hardware is common and not available unless listed. 7 32 33 34 31 28 29 30 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 50 24 Figure 16-1.
Eff w/LC552237 And Following (Kohler & Honda) TM-499 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 16-1. Main Assembly Quantity 1 +495 247 TOP , control box (specify color) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eff w/LC552237 And Following (Kohler & Honda) TM-499 Page 72 Description Part No. Dia. Mkgs. Item No. Figure 16-1. Main Assembly (Continued) Quantity 38 HM 176 365 METER, hour 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eff w/LC552237 And Following (Kohler & Honda) TM-499 Page 73 . Hardware is common and not available unless listed. Generator Power Panel 495 315 (USA) Generator Power Panel 495 219 (USA) Generator.
Eff w/LC552237 And Following (Kohler & Honda) TM-499 Page 74 Description Part No. Dia. Mkgs. Item No. Figure 16-2. Generator Power Panels (Figure 16-1, Item 39) Quantity Generator Power Panel 495 218 (USA) 1 495 220 P ANEL, generator power assembly 1 .
Notes.
PRINTED IN USA 2004 Miller Electric Mfg. Co. Miller Elect ric Mfg. Co. An Illinois T ool W orks Com pany 1635 West Spenc er S treet Applet on, W I 54914 US A International He adquarters − USA US.
An important point after buying a device Miller Electric TM-499C (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric TM-499C yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric TM-499C - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric TM-499C you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric TM-499C will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric TM-499C, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric TM-499C.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric TM-499C. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric TM-499C along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
