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February 1996
Form: TM-428
Effective With Serial No. JH242114

TECHNICAL MANUAL
Service And Parts

Miller Legend
(Formerly The Legend AEAD-200LE)
CC AC/DC Welding Generator For SMAW, GMAW, GTAW Welding

Welding
Mode

Weld
Output
Range

Rated
Welding
Output

Maximum
Open-Circu
it Voltage

CC/AC

35 – 225 A

225 A, 25 V,
100% Duty
Cycle

80

CC/DC

25 – 200 A

cover_tm 4/95 – ST-140 091-E

200 A, 25 V,
100% Duty
Cycle

72

Auxiliary Power
Rating

Fuel Capacity

Engine

Single-Phase,
5 kVA/kW, 42/21 A,
120/240 V AC, 60 Hz
And
Single-Phase,
1 kVA/kW, 9 A,
115 V AC, 100 Hz

7 5 gal (28 L) Tank
7.5

Onan P218 Air-Cooled,
Two-Cylinder, Four-Cycle,
Gasoline Engine

 1996 MILLER Electric Mfg. Co.

PRINTED IN USA

TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1.
1-2.
1-3.

1

Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
2

SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.

Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote 14 Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1.
3-2.
3-3.
3-4.

3
3
4
4
5
5
6
6
7

Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
8
8
9

SECTION 4 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

4-1.
4-2.
4-3.

100 Hz Auxiliary Power Receptacle And Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Auxiliary Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 Hz Auxiliary Power Receptacles And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10
10
11

SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13.

Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Circuit Diagram For Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control . .
Waveforms For Sections 6-2 And 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Control Board/Module PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Flowcharts For Idle Control Board/Module PC1 . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator Board PC2 Testing Information Prior To Serial No. KE604176 . . . . . . . .
Voltage Regulator Board PC2 Test Point Values Prior To Serial No. KE604176 . . . . . . . . .
Voltage Regulator Board PC2 Testing Information Effective With Serial No. KE604176 . . .
Voltage Regulator Board PC2 Test Point Values Effective With Serial No. KE604176 . . . .
Optional Remote Control Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Remote Control Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Remote Capacitor Board PC5 Testing Information Effective With
Serial No. KD346698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Optional Remote Capacitor Board PC5 Test Point Values Effective With
Serial No. KD346698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Replacing Brushes And Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15
18
20
22
23
24
26
26
27
27
28
28
29
29
30
32

WHO DO I CONTACT FOR HELP?
H CALL:
Miller Customer Service
Department at
414-735-4505

H FAX:
800-637-2348 (in USA),
or
414-735-4136 (outside USA)

H WRITE:
Miller Electric Mfg. Co.
P.O. Box 1079
Appleton, WI 54912 USA

Always provide Model Name and Serial or Style Number

OM-428N 1/96 – SPM-428C 6/94

SECTION 7 – DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1.
7-2.

33

Disassembly Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly Of Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33
34

SECTION 8 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil, Oil Filter, And Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting And Cleaning Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35
36
37
38
39
40
40

SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
safety_rtm1 4/95

1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.

Y Marks a special safety message.
. Means NOTE; not safety related.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary
actions to avoid the hazards.

1-2. Servicing Hazards

WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.
Only qualified persons should service, test, maintain, and repair this unit.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
1. Do not touch live electrical parts.
2. Stop engine before testing or repairing unit unless
the procedure specifically requires an energized
unit.
3. Insulate yourself from ground by standing or
working on dry insulating mats big enough to
prevent contact with the ground.
4. Do not leave live unit unattended.
5. When testing live unit, use the one-hand method.
Do not put both hand inside unit. Keep one hand
free.

MOVING PARTS can cause injury.
1. Keep away from moving parts such as fans, belts,
and rotors.
2. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
3. Keep hands, hair, loose clothing, and tools away
from moving parts.
4. Before working on generator, remove spark plugs
or injectors to keep engine from kicking back or
starting.
5. Block flywheel so that it will not turn while working
on generator components.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.

FLYING PIECES OF METAL or DIRT can
cause injury.
1. Always wear safety glasses with side shields or
face shield during servicing.
2. Be careful not to short metal tools, parts, or wires
together during testing and servicing.

STATIC ELECTRICITY can damage parts
on circuit boards.
1. Put on grounded wrist strap BEFORE handling
boards or parts.
2. Use proper static-proof bags to store, move, or
ship PC boards.

ENGINE EXHAUST GASES can kill.
1. Do not breathe exhaust fumes.
2. Use in open, well-ventilated areas, or vent
exhaust outside and away from any building air
intakes.
Miller Legend

ENGINE FUEL
explosion.

can

cause

fire

or

1. Stop engine before fueling.
2. Do not fuel while smoking or near sparks or
flames.
3. Do not overfill tank; clean up any spilled fuel.

BATTERY EXPLOSION can BLIND and
INJURE.
1. Always wear a face shield when working on a
battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.

BATTERY ACID can BURN SKIN.
1. Do not tip.
2. Replace damaged battery.
3. Flush eyes and skin immediately with water.

STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1. Check coolant level when engine is cold to avoid
scalding.
2. If the engine is warm and checking is needed,
follow steps 3 and 4.
3. Wear safety glasses and gloves and put a rag over
cap.
4. Turn cap slightly and let pressure escape slowly
before completely removing cap.

FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
1. Use equipment of adequate capacity to lift
components.
2. Use a lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
3. Securely attach components to lifting equipment.
TM-428 Page 1

HOT PARTS can cause severe burns.
1. Allow cooling period before servicing.
2. Wear protective gloves and clothing when working
on a hot engine.

ELECTRIC SHOCK HAZARD
incorrect use of test equipment.

from

1. Stop engine before making or changing meter
lead connections.
2. At least one meter lead should be a self-retaining
spring clip such as an alligator clamp.
3. Read instructions for test equipment.

MAGNETIC
CURRENTS
operation.

FIELDS FROM HIGH
can affect pacemaker

1. Pacemaker wearers keep away from servicing
areas until consulting your doctor.

UNCONTROLLED TILTING OR TIPPING
OF UNIT can result in personal injury
and equipment damage.
1. Do not put any body part under unit while lifting.
2. Use adequate blocks to support components as
needed during job.

HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services,
computers,
and
communications equipment.
1. Have only qualified persons familiar with
electronic equipment perform this installation.
2. The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
3. If notified by the FCC about interference, stop
using the equipment at once.
4. Have the installation regularly checked and
maintained.
5. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting,
and use grounding and shielding to minimize the
possibility of interference.

READ INSTRUCTIONS.
1. Use MILLER Testing Booklet (Part No. 150 853)
when servicing this unit.
2. Consult the Owner’s Manual for welding safety
precautions.

PINCH POINTS can injure.

3. Use only genuine MILLER replacement parts.

1. Be careful when working on stator and rotor
assemblies.

4. Reinstall injectors and bleed air from fuel system
according to engine manual.

1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is of
very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.”

TM-428 Page 2

To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are also recommended for pacemaker
wearers. Consult your doctor for complete information.

Miller Legend

SECTION 2 – INSTALLATION
2-1. Installing Welding Generator

Movement

Airflow

Location
18 in
(460 mm)

Y Do Not Lift Unit From End

18 in
(460 mm)

18 in
(460 mm)

OR
OR
18 in
(460 mm)

18 in
(460 mm)

Grounding

1
2
3

3

1

4

GND/PE

4
OR

Use #10 AWG or larger insulated
copper wire.
Y If unit does not have GFCI
receptacles, use GFCI-protected extension cord.

Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.

2

Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable

2
install1 10/95 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

2-2. Dimensions, Weights, And Operating Angles
Dimensions

A

B

Height

31-5/8 in (803 mm)

Y Do not exceed operating angles while
running or engine damage will occur.

Width

18 in (457 mm)

Y D
Do nott move or operate
t unit
it where
h
it could
ld
tip.

Depth

45 in (1143 mm)

A

16-1/2 in (419 mm)

B

32-3/4 in (832 mm)

C

13/16 in (21 mm) Dia.

25°
25°

25°

25°

Weight
C

Engine End
Miller Legend

Net

559 lb (254 kg)

Ship

600 lb (272 kg)
TM-428 Page 3

2-3. Fuel Consumption

SB-115 572

2-4. Engine Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface.
1/2 in
(13 mm)

Engine stops if oil pressure gets
too low.
Full

Full

ST-140 091-E / Ref. ST-151 983

TM-428 Page 4

Miller Legend

2-5. Connecting The Battery

Y Connect (–) cable last.

+

–

Tools Needed:
3/8, 1/2 in
Ref. ST-144 839-F / Ref. ST-168 046 / Ref. S-0756-D

2-6. Connecting To Weld Output Terminals
Y Use ONLY one set of terminals at a time. Disconnect
weld cables from set of weld
output terminals not in use.

Tools Needed:
3/4 in

Miller Legend

ST-140 092-B / Ref. ST-168 046

TM-428 Page 5

2-7. Selecting Weld Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less

150 ft
(45 m)

200 ft
(60 m)

250 ft
(70 m)

300 ft
(90 m)

350 ft
(105 m)

400 ft
(120 m)

Welding
Amperes

10 – 60%
Duty Cycle

60 – 100%
Duty Cycle

100

4

4

4

3

2

1

1/0

1/0

150

3

3

2

1

1/0

2/0

3/0

3/0

200

3

2

1

1/0

2/0

3/0

4/0

4/0

250

2

1

1/0

2/0

3/0

4/0

2-2/0

2-2/0

300

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

10 – 100% Duty Cycle

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

S-0007-D

2-8. Remote 14 Receptacle RC1 Information
Socket*

A
B

K

J
I

H
C L N
D M
G
E F

A

Socket Information

A

Contact closure to B completes 15 volts dc contactor control
circuit.

B

15 volts dc.

C

+4.5 volts dc output to remote control.

D

Remote control circuit common.

E

0 to +4.5 volts dc input command signal from remote control.

K

Chassis common.

ST-140 092-B

*The remaining sockets are not used.

TM-428 Page 6

Miller Legend

SECTION 3 – OPERATING WELDING GENERATOR
3-1. Front Panel Controls

5

6

1

2

7

3

4
Using Idle Lock Switch
RUN/IDLE

1860 rpm
(Power/Idle)

LOCK
RUN/IDLE

No Load:
1860 rpm
(Power/Idle)
Load:
3000 rpm
(Weld)

UNLOCK
RUN
OR
UNLOCK

3000 rpm
(Weld)
LOCK

Ref. ST-168 046

1 Engine Control Switch S2
Use switch to start engine, select speed,
and stop engine. In Run/Idle position, engine runs at power/idle rpm at no load, and
weld/power rpm under weld or 100 Hz auxiliary power receptacle load. In Run position,
engine runs at weld rpm.
2 Idle Lock Switch S1
Use switch to lock engine at power/idle
speed (see Table). In Unlock position, Engine Control switch and optional Remote
Control switch determine engine speed.
3 Engine Choke Control

Miller Legend

Use control to change engine air-fuel mix.

Use switch to select weld amperage range.

To Start: pull out choke and turn Engine
Control switch to Start position. Release
switch and slowly push choke in when engine starts. Do not crank engine while flywheel is turning.

. For best arc starts, use lowest amper-

To Stop: turn Engine Control switch to Off
position.
4 Remote Control Switch S4
Use switch to select front panel or remote
amperage control (see Section 3-2).
5 Ampere Ranges Switch S5

age range possible.

6

Fine Amperage Control R1

Use control to select weld amperage within
the range selected by the Ampere Ranges
switch. Control may be adjusted while welding. Scale is for reference only. Weld output
would be 88 A DC with control settings as
shown (50% of 70 to 105 A).
7

Engine Hour Meter HM

TM-428 Page 7

3-2. Remote Control (Optional)
Y Weld output terminals are
energized when Remote
Control switch S4 is in Panel/On position and engine is
running.

1

1

Remote 14 Receptacle RC1

Connect optional remote control to
RC1 (see Section 2-8).

In Example:
Min = 70 A DC
Percentage Of Range = 50%
Max = 88 A DC (50% of 70 to 105)

Max (88 A DC)

Min (70 A DC)

Set Switch

Set Range

Set Percentage

Adjust Remote Control
ST-140 092-B

3-3. Duty Cycle
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.

100% Duty Cycle at 225 Amperes AC

Continuous Welding
SB-115 570

TM-428 Page 8

Miller Legend

3-4. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of the welding generator. Curves of
other settings fall between the
curves shown.

SB-115 529-A / SB-115 528-A

Miller Legend

TM-428 Page 9

SECTION 4 – OPERATING AUXILIARY EQUIPMENT
4-1. 100 Hz Auxiliary Power Receptacle And Circuit Breaker
Y Do not operate 50/60 Hz or
60 Hz equipment from 100
Hz receptacle.
1

115 V 9 A 100 Hz AC Receptacle RC4

Receptacle supplies single-phase
power at weld speed only. Total
output available is 1 kVA/kW.
2
2

Circuit Breaker CB3

CB3 protects receptacle from
overload. If CB3 opens, receptacle
does not work.

1

Ref. ST-168 046

4-2. AC Auxiliary Power Curve

SB-115 571

TM-428 Page 10

Miller Legend

4-3. 60 Hz Auxiliary Power Receptacles And Circuit Breakers

For 60 Hz
Auxiliary Power
While Welding

LOCK

For 60 Hz
Auxiliary
Power Only

UNLOCK

RUN/IDLE

RUN/IDLE

4

0
PANEL

100

0
PANEL

ON

1

5

2

3

6

7

9

Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.
1

120 V 15 A AC Duplex Receptacle RC1

2

120 V 15 A AC Duplex Receptacle RC2

3

240 V 30 A Twistlock Receptacle RC3

Receptacles supply 60 Hz single-phase
power at power/idle speed only. Maximum
output from each duplex receptacle is is 2.5
kVA/kW. Maximum output from twistlock receptacle is 5 kVA/kW. For 60 Hz auxiliary
power, set controls as shown in table.
4

120 V 15 A AC Duplex GFCI Receptacles GFCI1 And GFCI2 (Optional)

If a ground fault is detected, the GFCI recep-

Miller Legend

tacle Reset button pops out and the circuit
opens to disconnect the faulty equipment.
Check for damaged tools, cords, plugs, etc.
connected to the receptacle. Press button to
reset receptacle and resume operation.

. At least once a month, run engine at

power/idle speed and press Test button
to verify GFCI is working properly.

5

Circuit Breaker CB5

6

Circuit Breaker CB7

100
ON

8

Ref. ST-168 046

8

Circuit Breaker CB2

CB1 and CB2 protect all the 60 Hz receptacles from overload. If CB1 or CB2 opens,
the 240 volt receptacle and one of the 120
volt receptacles does not work. 120 volts
may still be present at the 240 volt receptacle. Press button to reset breaker.
9

Total Auxiliary Power Output

Combined output of receptacles limited to
the 5 kVA/kW output of the generator:

CB5 protects RC1 and CB7 protects RC2
from overload. If CB5 or CB7 opens, the receptacle does not work. Press button to reset breaker.

EXAMPLE: If 10 A is drawn from a 120 V duplex receptacle, only 16 A is available at the
240 V receptacle:

7

(120 V x 10 A) + (240 V x 16 A) = 5.0 kVA/kW

Circuit Breaker CB1

TM-428 Page 11

SECTION 5 – THEORY OF OPERATION
1

Engine

Supplies force to turn revolving
fields.
2

Revolving Fields (Rotor)
13 ♦

Turn at 1860 rpm maximum for power/idle and 3000 rpm maximum for
weld. The speed and excitation current of the field coils determine voltages in stator windings.
3

Stator Windings

Supply power to exciter, auxiliary
power, and weld circuits.
4

Fuse F1

Protects exciter excitation winding
from overload.
5

Remote Control
Switch S4
Remote 14
12 ♦

12♦

Capacitor Board
PC5 And Remote 14
Receptacle RC1

Voltage
Regulator
Board PC2

Integrated Rectifier SR2
18
Fine
Amperage
Control R1

Control Relay CR5

Energizes when voltage is present in
exciter stator to disconnect field
flashing circuit.
7

Idle Module PC1 And Idle Lock
Switch S1

1

Voltage
Regulator

2
Revolving
Fields (Rotor)

Engine

Current Transformer CT1

Senses output from either weld or
100 Hz auxiliary power windings,
and signals PC1 to increase to or
maintain weld rpm.

Exciter

Fuse
F1

6♦

9
Control
Relay
CR5

CR3 energizes at power/idle rpm to
bypass fine amperage control R1.
7

Current
Transformer
CT1

7
Idle Module
PC1

11 Voltage Regulator Board PC2
And Transformer T1

12 Capacitor Board PC5, Remote
14 Receptacle RC1, Remote
Control Board PC3

Weld

4
Integrated
Rectifier SR2

Throttle
Solenoid
TS1

CR2 energizes at weld rpm to supply
power to throttle solenoid TS1.

PC2 monitors 50/60 Hz auxiliary
power voltage through T1, and maintains proper output by adjusting field
current.

100 Hz
Auxiliary
Power

5

8

10 Control Relays CR2, CR3, CR4

CR4 energizes at power/idle rpm to
provide 50/60 Hz auxiliary power
output.

60 Hz Auxiliary
Power

Stator Windings

Throttle Solenoid TS1

Increases engine speed to weld rpm
when energized.
9

CR3

3

PC1 and S1 control engine speed.
Without a signal from CT1, PC1 lowers engine speed to power/idle rpm.
8

Remote
Control Board
PC3
11

Changes ac output of stator windings to dc to supply excitation current
to the exciter revolving field.
6

Panel

10
Control Relays
CR2, CR3, CR4

16
Circuit
Breaker
CB3

Idle Lock
Switch S1

17
100 Hz
Auxiliary Power
Receptacle RC4

PC5 protects unit from high frequency. RC1 connects remote amperage
and contactor control to unit through
control board PC3.

TM-428 Page 12

Miller Legend

13 Remote Control Switch S4
Selects Panel or remote amperage
control.
14 Circuit Breakers CB1, CB2,
CB5, And CB7
Protect 50/60 Hz auxiliary power
receptacles RC1, RC2, and RC3
from overload.
15 50/60 Hz Auxiliary Power Receptacles RC1, RC2, And
RC3
Provide connection points and
power for auxiliary equipment.
16 Circuit Breaker CB3
Protects 100 Hz auxiliary power receptacle RC4 from overload.
17 100 Hz Auxiliary Power Receptacle RC4
Provides connection point and
power for auxiliary equipment
while welding.
18 Fine Amperage Control R1
11

Adjusts amperage within range selected by Ampere Ranges switch
S5.

CR4
Transformer
T1

19 Ampere Ranges Switch S5
Selects coarse range of weld output from weld stator.
14

15
Circuit
Breakers
CB1, CB2,
CB5, CB7

20 Reactor AC-Z

50/60 Hz
Auxiliary Power
Receptacles
RC1, RC2, RC3

Tapped reactor limits weld output
and provides coarse ranges.
21 Main Rectifier SR1
Changes ac output from weld
windings to dc.
22 Stabilizer DC-Z

19

Smooths out current to dc weld
output terminals.
Ampere
Ranges
Switch S5

23 HF Filter Board PC4
Protects unit from high frequency.
24 Positive (+) And Negative (–)
DC Weld Output Terminals
23

20

25

Provide dc weld output.
25 Electrode And Work AC Weld
Output Terminals

Electrode And
Work AC Weld
Output Terminals

Reactor
AC-Z

Provide ac weld output.

21
Main
Rectifier
SR1

HF Filter
Board
PC4
AC Or DC Control Circuits

22
Stabilizer
DC-Z

Miller Legend

24
Positive (+) And
Negative (–) DC
Weld Output
Terminals

Weld Current Circuit
Mechanical Coupling
Magnetic Coupling

♦

Optional

TM-428 Page 13

NOTES

TM-428 Page 14

Miller Legend

SECTION 6 – TROUBLESHOOTING
6-1. Troubleshooting Tables
A. Welding

. See Sections 6-2 and 6-3 for test

points and values and Section 10
for parts location.

Trouble
No weld output.

Remedy
Check fuse F1, and replace if necessary (see Section 8-6).
Check integrated rectifier SR2, and replace if necessary.
Check diode D4, and replace if necessary.
Clean slip rings, and install new brushes if necessary (see Section 6-15).
Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotor
if necessary.
Check resistance and connections of resistors R2 and R4; R2 and R4 are each 12 ohms ±10%. Replace resistor(s) if necessary. Adjust R2 and R4 according to Section 6-16.
Check resistance and connections of Fine Amperage Control R1; R1 is 0 to 30 ohms ±10%. Replace
R1 if necessary (see Section 3-1).
Disconnect leads 22 and 29 from SCR/integrated rectifier SR2, and check for continuity between leads
22 and 29. Replace exciter stator if necessary.
For units with optional remote control, check capacitor C5 for a short or open, and check for proper connections. Replace C5 if necessary.
Check voltage regulator board PC2 and connections, and replace if necessary (see Section 6-9).

No or erratic weld output.

Clean and tighten weld connections both inside and outside unit.
Check engine speed, and adjust if necessary (see Section 8-5).
Check to make sure Ampere Ranges switch S5 is not between positions. Check continuity of S5, and
replace if necessary.
Check reactor AC-Z for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace AC-Z if necessary.
Check resistance and connections of Fine Amperage control R1; R1 is 0 to 30 ohms ± 10%. Replace
R1 if necessary.
Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotor
if necessary.

No or erratic DC weld output only.

Check modular main rectifier SR1, and replace if necessary.
Check stabilizer DC-Z for signs of winding failure. Check continuity across windings, and check for
proper connections. Replace DC-Z if necessary.

Low or high weld output.

Check engine speed, and adjust if necessary (see Section 8-5).
Adjust resistor R4 slider until 128 to 132 volts ac is obtained at 100 Hz receptacle RC4 (see Section
6-16).
Adjust resistor R2 slider until proper open-circuit-voltage is obtained at weld output terminals (see Section 6-16).
Check resistance and connections of resistor R3 on suppressor R3, VR1 module; R3 is 1000 ohms ±
10%. Replace R3, VR1 module if necessary.
Check reactor AC-Z for signs of winding failure. Check continuity across windings, and check for proper
connections. Replace AC-Z if necessary.

Miller Legend

TM-428 Page 15

B. 50 Or 60 Hz Auxiliary Power
Trouble

Remedy

No auxiliary power output at recep- Run engine at power/idle speed.
tacles RC1, RC2, or RC3.
Reset circuit breakers CB1 and CB2. Effective with Serial No. KE629034, also reset circuit breakers
CB5 and CB7 (see Section 4-3).
Check receptacles RC1, RC2, RC3 for continuity and proper connections. Replace receptacle(s) if necessary.
Check connections to terminal strip 1T.
Clean slip rings, and install new brushes if necessary (see Section 6-15).
Check coil voltage and connections of control relay CR4. Check continuity of coil and condition of contacts. Replace CR4 if necessary.
Check diode D4, and replace if necessary.
Check idle board/module PC1 and connections (see Section 6-5).
Check control transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check primary and secondary voltages. Replace T1 if necessary.
Disconnect leads 21, 23, and 33 from brushes, and check continuity across slip rings. Replace rotor
if necessary.
Disconnect leads 48 and 49 from voltage regulator board PC2, and check continuity between leads 48
and 49. Disconnect leads 50, 51, 52, and 53 from stator. Check continuity between leads 50 and 51,
and 52 and 53. Replace stator if necessary.
Low auxiliary power output.

Check connections to terminal strip 1T.
Clean slip rings, and install new brushes if necessary (see Section 6-15).
Check integrated rectifier SR2, and replace if necessary.
Check coil voltage and connections of control relay CR3. Check continuity of coil and condition of contacts. Replace CR3 if necessary.
Check voltage regulator board PC2 and connections, and replace if necessary.

High auxiliary power output.

Check engine speed, and adjust if necessary.
Check voltage regulator board PC2 and connections, and replace if necessary (see Section 6-9).

C. 100 Hz Auxiliary Power
Trouble

Remedy

No auxiliary power output at receptacle Run engine at weld speed.
RC4.
Reset circuit breaker CB3 (see Section 4-1).
Check receptacle RC4 for continuity and proper connections. Replace receptacle if necessary.
Disconnect leads 90, 91, 92, and 93 from stator. Check continuity between leads 90 and 91, and 92 and
93. Replace stator if necessary.
Check diode D4, and replace if necessary.

TM-428 Page 16

Miller Legend

D. Engine
Trouble
Engine will not start.

Remedy
Check fuel level (see Section 2-4).
Check battery and engine charging system according to engine manual.
Check continuity of Engine Control switch S2, and replace if necessary.
See engine manual.

Engine starts but stops as soon as En- Check oil level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual
gine Control switch S2 returns to Run for location). S3 should close when engine is running.
position.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see engine
manual).
Check continuity of Engine Control switch S2, and replace if necessary.
Engine stopped during normal opera- Check oil level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual
tion.
for location). S3 should close when engine is running.
Check continuity of Engine Control switch S2, and replace if necessary.
Battery discharges between uses.

Make sure Engine Control switch S2 is placed in the Off position when engine is not in use (see Section
3-1).
Prior to Serial No. KA780044, check fuse F2 and replace if necessary.
Clean battery, terminals and posts with baking soda solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Check voltage regulator according to engine manual.
Replace battery.

Engine idles, but does not come up to Wait 10 seconds for throttle solenoid circuit breaker CB4 to reset (see Section 8-6).
weld speed.
Place Idle Lock switch S1 in Unlock position (see Section 3-1).
Check continuity and connections of current transformer CT1, and replace if necessary.
Check continuity of Engine Control switch S2, and replace if necessary.
Check coil voltage and connections of control relay CR2. Check continuity of coil and condition of contacts. Replace CR2 if necessary.
Check diode D6 in throttle solenoid TS1 circuit, and replace if necessary.
Check resistance at throttle solenoid TS1 terminals. With plunger out, resistance is less than 1 ohm.
With plunger bottomed, resistance is 17 ohms ±10%.
Check throttle linkage for smooth, non-binding operation.
Check idle board/module PC1 and connections, and replace if necessary (see Section 6-5).
Engine does not return to idle speed.

Remove weld load.
Check continuity of Engine Control switch S2, and replace if necessary.
Check throttle linkage for smooth, non-binding operation.

Unstable or sluggish engine speeds.

Readjust throttle linkage if necessary.
Tune-up engine according to engine manual.

Miller Legend

TM-428 Page 17

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 9

d)

Stop engine before checking resistance

R1

29 ohms

R2

34 ohms

R3

35 ohms

R4

2 ohms

R5

2 ohms

R6 thru R17

Less than 1 ohm

R18

Pull: Less than 1 ohm Hold: 16.5 ohms

Test Equipment Needed:

See Section
6-16 for R2 and
R4 adjustment

V14/R17

I2

I1

V15

R1

V16/
R16

R2

V17/
R15
R14

R13

V18
V11,
V12,
V13/R12
Throttle
control relay
CR2 energized
at weld rpm

V19

R18
See Section 6-5
for PC1 data

TM-428 Page 18

Field current
control relay CR3
and auxiliary power
control relay CR4
energized at
power/idle rpm

Miller Legend

Amperage Readings
a)

Tolerance – ±5% unless specified

b)

Condition – 70°F (21°C); cold machine
(no warm-up); no load

I1

3 amps dc

I2

1.8 amps dc (R1 at min.)
3.1 amps dc (R1 at max.)

Voltage Readings
a)
b)
c)
d)

V6/R3

R6

V8/
R5

R7

V5

V7/
R4

V4
See Sections 6-7
thru 6-9 for PC2 data
V10/R8

R11

V9/R9

V3

R10

See Section 5 for
PC4 information
V2/C/D

Tolerance – ±10% unless specified
Condition – 70°F (21°C); cold
machine (no warm-up); no load
Reference – to circuit common
(lead 33) unless noted
Wiring Diagram – see Section 9

V1

DC/CC OCV at weld rpm:
58 volts dc (R1 at min.)
70 volts dc (R1 at max.)
(Do not exceed 72 volts dc)

V2

AC/CC OCV, at weld rpm:
65 volts ac (R1 at min.)
80 volts ac (R1 at max.)
(Do not exceed 80 volts ac)

V3

At RC3 at power/idle rpm:
244 volts ac ±5% (50 or 60 Hz)

V4

At RC2 at power/idle rpm:
122 volts ac ±5% (50 or 60 Hz)

V5

At RC1 at power/idle rpm:
122 volts ac ±5% (50 or 60 Hz)

V6

AC input to transformer T1: 122 volts ac
(power/idle rpm), 0 volts ac (weld rpm)

V7

AC output to PC2: 21 volts ac ±5%

V8

AC output to PC2: 21 volts ac ±5%

V9

AC output from Regulator Power
Winding (power/idle rpm)
158 volts ac ±5%

V10

AC output from Weld Winding at
weld rpm: 65 volts ac (R1 at min.), 80
volts ac (R1 at max.) (Do not exceed 80
volts ac)

V11

At rated DC weld load: At least
1 volts ac

V12

At weld rpm and 100 watt light bulb load
applied: 3 volts ac or greater

V13

Idle Lock switch S1 in Lock:
0 volts ac at all times

V14

AC output from Exciter Winding
80 volts ac (power/idle rpm)
145 volts ac (weld rpm)

V15

At RC4 at weld speed: at least 120
volts ac (Do not exceed 132 volts ac)

V16

Auxiliary power winding at weld rpm:
at least 120 volts ac (Do not exceed
132 volts ac)

V17

Auxiliary power winding at weld rpm:
at least 120 volts ac (Do not exceed
132 volts ac)

V18

Battery output whenever engine is
running: 14 volts dc.

V19

AC Alternator output:
17 volts ac (power/idle rpm)
39 volts ac (weld rpm)

V1/A/B

See Section 6-4 for
waveforms A thru D

SC-168 053-A

Miller Legend

TM-428 Page 19

6-3. Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control
Resistance Values
a)

Tolerance – ±10% unless specified

b)

Condition – 70°F (21°C); cold
machine (no warm-up)

c)

Wiring Diagram – see Section 9

d)

Stop engine
resistance

before

R1

29 ohms

R2

34 ohms

R3

35 ohms

R4

2 ohms

R5

2 ohms

R6 thru R17

Less than 1 ohm

Test Equipment Needed:

checking

See Section 6-13
for PC5 data

See Section
6-11
for PC3 data

V14/R17

Field flashing
disconnect relay CR5

I2

I1

See Section
6-16 for R2 and
R4 adjustment

V15
R1

V16/
R16

R2

V17/
R15
R14

R13

V11, V12,
V13/R12

V18

Throttle
control relay
CR2 energized
at weld rpm

V19

TM-428 Page 20

See Section 6-5
for PC1 data

Field current
control relay CR3
and auxiliary power
control relay CR4
energized at
power/idle rpm

Miller Legend

Amperage Readings
a)

Tolerance – ±5% unless specified

b)

Condition – 70°F (21°C); cold machine
(no warm-up); no load

I1

3 amps dc

I2

1.8 amps dc (R1 at min.)
3.1 amps dc (R1 at max.)

Voltage Readings
a)
b)
c)
d)

V7/
R4

V4

V2

AC/CC OCV, at weld rpm:
65 volts ac (R1 at min.)
80 volts ac (R1 at max.)
(Do not exceed 80 volts ac)

V3

At RC3 at power/idle rpm:
244 volts ac ±5% (50 or 60 Hz)

V4

At RC2 at power/idle rpm:
122 volts ac ±5% (50 or 60 Hz)

V5

At RC1 at power/idle rpm:
122 volts ac ±5% (50 or 60 Hz)

V6

AC input to transformer T1: 122 volts ac
(power/idle rpm), 0 volts ac (weld rpm)

V7

AC output to PC2: 21 volts ac ±5%

V8

AC output to PC2: 21 volts ac ±5%

V9

AC output from Regulator Power
Winding (power/idle rpm)
158 volts ac ±5%

V10

AC output from Weld Winding at
weld rpm: 65 volts ac (R1 at min.), 80
volts ac (R1 at max.) (Do not exceed 80
volts ac)

V11

At rated DC weld load: At least
1 volts ac

V12

At weld rpm and 100 watt light bulb load
applied: 3 volts ac or greater

V13

Idle Lock switch S1 in Lock:
0 volts ac at all times

V14

AC output from Exciter Winding
80 volts ac (power/idle rpm)
145 volts ac (weld rpm)

V15

At RC4 at weld speed: at least 120
volts ac (Do not exceed 132 volts ac)

V16

Auxiliary power winding at weld rpm:
at least 120 volts ac (Do not exceed
132 volts ac)

V17

Auxiliary power winding at weld rpm:
at least 120 volts ac (Do not exceed
132 volts ac)

V18

Battery output whenever engine is
running: 14 volts dc.

V19

AC Alternator output:
17 volts ac (power/idle rpm)
39 volts ac (weld rpm)

V3
R11

V9/R9

See Sections 6-7
thru 6-9 for PC2 data
R10

V2/C/D

DC/CC OCV at weld rpm:
58 volts dc (R1 at min.)
70 volts dc (R1 at max.)
(Do not exceed 72 volts dc)

V5

V8/
R5

R7

V10/R8

V1

V6/R3

R6

See Section 5 for
PC4 information

See Section 6-4 for
waveforms A thru D

V1/A/B

Tolerance – ±10% unless specified
Condition – 70°F (21°C); cold
machine (no warm-up); no load
Reference – to circuit common
(lead 33) unless noted
Wiring Diagram – see Section 9

SC-168 054-A

Miller Legend

TM-428 Page 21

6-4. Waveforms For Sections 6-2 And 6-3

2 ms 50 V

2 ms 10 V

gnd

gnd

A. DC Open-Circuit Voltage, Ampere Ranges
Switch S5 In Max Position

B. DC Weld Output, 25 Volts DC, 100 Amperes, Ampere Range Switch S5 In 70-105
Position (Resistive Load)

5 ms 50 V

5 ms 20 V

gnd

gnd

C. AC Open-Circuit Voltage, Ampere Ranges
Switch S5 In Max Position

D. AC Weld Output, 25 Volts AC, 100 Amperes,
Ampere Range Switch S5 In 70-105 Position
(Resistive Load)

Waveforms shown are for 60 Hertz models;
waveforms for 50 Hertz models are similar.

Test Equipment Needed:

TM-428 Page 22

Miller Legend

6-5. Idle Control Board/Module PC1 Testing Information
Be sure plugs are secure before
testing. See Section 6-6 for specific values during testing.
1
2

Idle Control Board PC1 (Prior
To Serial No. JH300534)
Idle Module PC1 (Effective
With Serial No. JH300534)

1

OR
2

Test Equipment Needed:

Ref. ST-800 698-A / SC-113 702-A

Miller Legend

TM-428 Page 23

6-6. Troubleshooting Flowcharts For Idle Control Board/Module PC1

Engine does not go to power/idle rpm
with no weld load applied.

Engine does not go to weld rpm with
load applied.

Connect meter (AC) between
terminal G and terminal E.

Connect meter (DC) between
terminal B (+) and terminal E (–).

Start engine. Place Engine Control
switch S2 in Run/Idle position.

Start engine. Place Engine Control
switch S2 in Run/Idle position; Idle
Lock switch S1 in Unlock position.

NO
0 (zero) volts ac present?

Check for internal
load such as
shorted diode in
main rectifier SR1.

YES

+12 volts dc present?
YES

Check connections
to Engine Control
switch S2 and
ground connection
(lead 33).

Connect meter (AC) between
terminal G and terminal E.

Connect meter (DC) between
terminal D (+) and E (–).

0 (zero) volts dc present?

NO

NO

Check connections
to Engine Control
switch S2.

Start engine. Place Engine
Control switch in Run/Idle position.

YES
Connect a 100 watt light bulb to
100 Hz ac receptacle.

Connect meter (DC) between
terminal C (+) and terminal E (–).

0 (zero) volts dc
present after 12 to 18 seconds?
YES
Check throttle solenoid TS1
linkage.

NO

Replace idle
board/module
PC1

NO
Minimum of 1 volt ac present?
YES
Connect meter (DC) between
terminal C (+) and terminal E (–).

NO
Reinstall cover.

Check connections
to current
transformer CT1.

+12 volts dc present?

Replace idle
board/module
PC1

YES
Check circuit breaker CB4, throttle
solenoid TS1 connections and
linkage, and control relay CR2.

Disconnect 100 watt light bulb
and meter leads.

Reinstall cover.

TM-428 Page 24

Miller Legend

Engine does not go to weld rpm with
Engine Control switch S2 in Run position.

Control Relays CR3 and CR4 do not
energize at idle rpm (See Section 5 for
CR3 and CR4 information)
Connect meter (DC) between
terminal A (+) and F (–) prior to
Serial No. JH300534, or B (+) and
F (–) effective with Serial No.
JH300534.

Connect meter (DC) between
terminals D (+) and E (–).

Start engine. Place Engine
Control switch S2 in Run position.

Start engine. Place Engine
Control switch in Run position.

Prior to Serial No. JH300534,
move Weld/Power switch S1 to
Weld position.

NO
+12 volts dc present?
YES

Check connections
to Engine Control
switch S2 and
ground connection
(lead 33).

NO

Replace idle
board/module
PC1

Place Engine Control switch S2
in Run/Idle position.

+12 volts dc present?
NO

YES

Replace idle
board/module
PC1

YES

Connect meter (DC) between
terminals C (+) and E (–).

+12 volts dc present?

NO
0 (zero) volts dc present?

Replace idle
board/module
PC1

YES
Check control relays
CR3 andCR4.

Check circuit breaker CB4, throttle
solenoid TS1 connections and
linkage, and control relay CR2.
Reinstall cover.

Reinstall cover.

Miller Legend

TM-428 Page 25

6-7. Voltage Regulator Board PC2 Testing Information Prior To Serial No. KE604176
2

1

Be sure plugs are secure before
testing. See Section 6-8 for specific values during testing.
1
2

Voltage Regulator Board PC2
Terminals A Thru G

Test Equipment Needed:

Ref. ST-800 698-A / SA-099 497-B

6-8. Voltage Regulator Board PC2 Test Point Values Prior To Serial No. KE604176
a) Tolerance – ±10% unless
specified
PC2 Voltage Readings

Receptacle

Value

A

Circuit common

B

18 volts ac input with respect to pin A

C

18 volts ac input with respect to pin A

D

Circuit common

E

130 volts ac input with respect to terminal G at power/idle rpm

F

55 volts dc output with respect to terminal D at power/idle rpm

G

130 volts ac input with respect to terminal E at power/idle rpm

TM-428 Page 26

b) Reference – to circuit common (lead 33) unless noted

Miller Legend

6-9. Voltage Regulator Board PC2 Testing Information Effective With Serial No.
KE604176
1

Be sure plugs are secure before
testing. See Section 6-10 for specific values during testing.

2

1
2

Voltage Regulator Board PC2
Receptacle RC1

Test Equipment Needed:

Ref. ST-800 698-A / SA-160 889-A

6-10. Voltage Regulator Board PC2 Test Point Values Effective With Serial No. KE604176
a) Tolerance – ±10% unless
specified
PC2 Voltage Readings

b) Reference – to circuit common (lead 33) unless noted

Receptacle

Pin

RC1

1

18 volts ac input with respect to pin 5

2

Not used

3

18 volts ac input with respect to pin 5

4

Circuit common

5

Circuit common

6

130 volts ac input with respect to pin 8 at power/idle rpm

7

Not used

8

130 volts ac input with respect to pin 6 at power/idle rpm

9

55 volts dc output with respect to pin 4 at power/idle rpm

Miller Legend

Value

TM-428 Page 27

6-11. Optional Remote Control Board PC3 Testing Information
1

Be sure plugs are secure before
testing. See Section 6-12 for specific values during testing.
1
2

Remote Control Board PC3
Receptacle RC1

2

Test Equipment Needed:

Ref. ST-800 698-A / ST-115 941-L / SA-138 247

6-12. Optional Remote Control Board PC3 Test Point Values
a) Tolerance – ±10% unless
specified
PC3 Voltage Readings

b) Reference – to circuit common (lead 33) unless noted

Receptacle

Pin*

RC1

1 (A)

Circuit common

2 (B)

Circuit common

3 (C)

+50 volts dc input at power/idle rpm; 100 volts dc input at weld rpm

4 (D)

+12 volts dc input with respect to pin 5 at power/idle or weld rpm

5 (E)

Chassis ground (lead 33)

6 (F)

59 to 6.8 volts dc output with respect to pin 1 from min to max of remote control with remote contactor control switch closed, 130 volts dc output with remote contactor control switch open

7 (G)

Circuit common

8 (H)

Command reference output, +4.5 volts dc output with respect to pin 7

9 (J)

0 volts dc output with remote contactor control switch closed, +15 volts dc output with remote contactor control switch open

10 (K)

Value

0 to +4.5 volts dc input from min to max of Fine Amperage control R1 at power/idle rpm

*Letter(s) in parenthesis ( ) is pin letter prior to Serial No. KA840710.
TM-428 Page 28

Miller Legend

6-13. Optional Remote Capacitor Board PC5 Testing Information Effective With Serial No.
KD346698
4

Be sure plugs are secure before
testing. See Section 6-14 for specific values during testing.

3

1
2
3
4

Capacitor Board PC5
Remote 14 Receptacle RC1
Receptacle RC2
Terminal K

2
1

Test Equipment Needed:

Ref. ST-800 698-A / SA-156 026-C

6-14. Optional Remote Capacitor Board PC5 Test Point Values Effective With Serial No.
KD346698
a) Tolerance – ±10% unless
specified
PC5 Voltage Readings

b) Reference – to circuit common (lead 33) unless noted

Receptacle

Pin

RC1

A

Contact closure to pin B completes the dc contactor control circuit

B

+15 volts dc output

C

Command reference, +4.5 volts dc output

D

Remote control circuit command

E

Input command signal from potentiometer wiper, 0 to +4.5 volts dc input

K

Chassis ground (lead 33)

1

Remote control circuit common

2

Command reference, +4.5 volts dc input

3

+15 volts dc input

4

Command signal from potentiometer wiper, 0 to +4.5 volts dc output

5

Not used

6

Contact closure to pin 3 completes contactor control circuit

K

Chassis ground (lead 33)

RC2

Terminal
Miller Legend

Value

TM-428 Page 29

6-15. Replacing Brushes And Cleaning Slip Rings
A. Checking Brushes And Cleaning Slip Rings
Stop engine and allow to cool.
1

Brush Holder Retaining Bar

2

Brush Holder Bracket

Remove brush holder bracket.
Keep hardware for reinstallation.
3

Brush Holder

4

Brush With Spring

5

Brush Holder Cap

Mark and disconnect leads at
caps, and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6

Slip Rings

Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as
little material as possible. Stop engine.
Install brushes, bracket, and remaining generator parts. Adjust
brushes as shown in Section B.
Reinstall both side panels and top
cover.

2
5
3
4

1
5/16 in. (8 mm)
Minimum Length
9/16 in. (14.3 mm)
New Length

Replace
Damaged Brushes

Tools Needed:
1/2 in

ST-800 698-A / Ref. ST-115 942-F / S-0233-A

TM-428 Page 30

Miller Legend

B. Adjusting Brush Position
Stop engine.
After installing brushes, adjust
brush position as follows:
1

Brush Holder

2

Brass Sleeve

3

Brush

4

Slip Ring

Loosen brush holder bracket
mounting hardware. Move bracket
until brass sleeves are positioned
as shown. Tighten hardware.
Reinstall side panels and cover.
If operation is still not okay, have a
qualified machine shop turn and
polish slip rings.

Side View
3/32 in
(2.4 mm)

3 2

1

4

Correct Brush Position

Incorrect Brush Position
Top View

Center brushes on slip
rings.
4

3 2 1

Correct
Brush Position

Incorrect
Brush Position

Tools Needed:
3/8, 1/2 in

Ref. ST-800 698-A / Ref. ST-800 677-B

Miller Legend

TM-428 Page 31

6-16. Checking Unit Output After Servicing
Check engine speeds, and adjust
if necessary (see Section 8-5).
1

115 VAC 100 Hz Receptacle
RC4

With no load applied and engine
running at weld rpm, there should
be 128 to 132 volts ac present at
RC4.
2

Slider

3

Resistor R4

Y Stop engine before adjusting R4
If necessary, adjust slider on R4
until 128 to 132 volts ac is obtained
at RC4. Do not exceed 132 volts
ac.
4

DC Weld Output Terminals

Turn Fine Amperage control R1 to
max. With no load applied and engine running at weld rpm, there
should be 70 to 72 volts dc present
at dc weld terminals.

1

2

5
5

4

Resistor R2

Y Stop engine before adjusting R2
If correct voltage is not present, adjust slider on R2 until correct voltage is obtained at dc weld terminals. Do not exceed 72 volts dc.

2
3

Stop engine. Allow engine to cool,
and then complete pre-operational
checks in table.
Reinstall cover and side panels.

Pre-Operational Checks
Wipe engine surfaces clean.
Check labels; replace labels that are unreadable or damaged.
Check fuel and oil (see Section 2-4).
Check and correct any fluid leaks.
Clean weld output and battery terminals. Tighten connections.
Clean outside of entire unit.

Tools Needed:

Ref. ST-800 698-A / ST-800 249

TM-428 Page 32

Miller Legend

SECTION 7 – DISASSEMBLY AND REASSEMBLY
7-1. Disassembly Of Unit
Use Section 6-1 to determine if
trouble is in rotor, stator, engine or
a combination of these components.
Remove sheet metal panels from
unit. Disconnect negative (–) battery cable from battery. Remove
spark plugs. Mark and disconnect
all stator leads.
Y Do not damage rotor or stator during this procedure.
Use hoist and lifting strap to remove the engine/generator assembly.

Tools Needed:

3/8, 7/16, 1/2, 9/16 in
ST-800 710-A

Miller Legend

TM-428 Page 33

7-2. Disassembly Of Generator

Hardware may differ from that shown.

Torques:
Prior To Serial No. KD523655

Effective With Serial No. KD523655

A

15 ft lb (20

N.m)

A

15 ft lb (20 N.m)

B

30 ft lb (41 N.m)

B

20 ft lb (27 N.m)

C

25 ft lb (34

N.m)

C

25 ft lb (34 N.m)

D

15 ft lb (20 N.m)

D

20 ft lb (27 N.m)

E

15 ft lb (20 N.m)

E

15 ft lb (20 N.m)

5

A
B
C
6
D
7
8

4
3

9

2

10

1
11
12

16
E

15
14

13
ST-115 942-F

Y Do not damage stator or rotor windings during this procedure.

6

Fan Rotor Adapter

16 Brush Holder

7

Rotor Fan

Reassembly

8

Rotor

With engine properly supported with blocks,
remove hardware securing stator to engine.

9

Ball Bearing

Remove generator parts as needed:

10 Retaining Ring

1

Fan Guard

11 Integrated Rectifier SR2

2

O-Ring

12 Brush Holder Bracket

3

Endbell

13 Brush Holder Retaining Bar

4

Stator Assembly

14 Brush Holder Cap

Use cable ties to secure leads in existing
wiring harnesses and away from moving or
hot parts.

5

Engine Adapter

15 Brush

Reconnect negative (–) battery cable.

Disassembly

TM-428 Page 34

Reinstall engine and generator parts as
needed (see torque table).
Reconnect fuel line, choke cable, and base
ground cable. Reinstall spark plugs, battery
and tray, panels, and cover.

Miller Legend

SECTION 8 – MAINTENANCE
8-1. Routine Maintenance
Y Stop engine before maintaining.

Recycle engine
fluids.

. See also Engine Manual and mainte-

nance label. Service engine more often
during severe conditions.

8 Hours
Wipe Up
Spills

OIL
Full

Check Fluid
Levels.
See Section 2-4

20 Hours
Check And
Clean Spark
Arrestor Screen

25 Hours
Clean And
Check Air
Cleaner

50 Hours
Clean And
Tighten Weld
Terminals

100 Hours
Change Oil. See
Section 8-4 And
Maintenance
Label

Change Oil Filter. See
Section 8-4 And
Maintenance Label

Clean Cooling
System,
See Engine
Manual

Clean And
Tighten
Battery
Connections

200 Hours
Replace
Fuel Filter.
See Section
8-4.

Check
Valve
Clearance

Replace
Unreadable
Labels

500 Hours
Check
Spark
Plugs

Repair Or Replace
Cracked Cables

1000 Hours
OR

Miller Legend

Blow Out Or Vacuum Inside.
During Heavy Service,
Clean Monthly
TM-428 Page 35

8-2. Maintenance Label
ONAN P218 GAS ENGINE
See Engine Manual for complete engine care. Give engine
Specification and Serial Number when ordering parts.

°C

To Drain Oil:

30

+20
1/2 in. ID Hose

+10
+40

Pull

0

10W

Check
daily.

°

F
+100

+30

Push And
Turn CCW

5W-30

Recommended Oil . . . API Service Classification -10
SF, SG, SF/CC, SG/CE
-20
0
Oil & Filter Change . . . . . . . . . .
-30
dirty conditions . . . 25 hours or less
normal conditions . 100 hours
Oil Filter . . . . . . . . . . . . MILLER 065 251, Onan 122-0645
Oil Capacity . . . . . . . . 1.5 qt (1.4 L) or 1.75 qt (1.6 L) with filter change
Fuel Grade . . . . . . . . . Regular or Unleaded
Fuel Filter . . . . . . . . . . MILLER 066 113, Onan 149-2206-01,
Fram G10E1

Gasoline
Air Filter Service . . . . 100 hours or less – see Owner’s Manual
Air Filter Element . . . . MILLER 064 617, Onan 140-2522
Air Filter Wrapper . . . . MILLER 065 653, Onan 140-1496
+

12 Volt Battery . . . . . . . . . . . . . . . . . . . . . . . . BCI Group 58
Cranking Performance at 0°F (-18°C) . . . . 430 Amps min.
Engine RPM – No Load
Power . . . 1650 (50 Hz)
1860 (60 Hz)
Weld . . . . . 3000

Valve Clearance – Cold
In. . . . 0.005 in (0.13 mm)
Ex. . . 0.013 in (0.33 mm)

Spark Plug Gap . . . . . 0.025 in. (0.6 mm)
Spark Plug . . . . . . . . . Champion RS17YX Preferred or
RS14YC

Use only resistor spark plugs and wires.
Spark Arrestor Inspection And Service . 20 operating hours see Owner’s Manual

Optional

TM-428 Page 36

S-176 891

Miller Legend

8-3. Servicing Air Cleaner
Y Do not run engine without
air cleaner or with dirty element.
1

Stop engine.
1

2

Precleaner

Wash precleaner with soap and
water solution. Allow precleaner to
air dry completely.
Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.
2

Element

Replace element if dirty or oily.

oil

aircleaner3 1/96 – ST-156 852 / S-0759

Miller Legend

TM-428 Page 37

8-4. Changing Engine Oil, Oil Filter, And Fuel Filter
Stop engine and allow to cool.
1

Oil Drain Valve

2

1/2 ID x 12 in Hose

3

Oil Filter

Change engine oil and filter according to engine owner’s manual.
Y Close valve and valve cap
before adding oil and running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 8-2).
Full

4

Fuel Filter

5

Fuel Line

Replace line if cracked or worn.
Install new filter. Wipe up any
spilled fuel.
Start engine, and check for fuel
leaks.
Stop engine, tighten connections
as necessary, and wipe up fuel.

4

5

3

2

1

Tools Needed:

ST-140 091-E / ST-144 840-C Ref. ST-168 046 / ST-800 395 / S-0842

TM-428 Page 38

Miller Legend

8-5. Adjusting Engine Speed
After tuning engine, check engine
speeds with a tachometer. See
table for proper no load speeds. If
necessary, adjust speeds as follows:
Start engine, and place Engine
Control switch in Run/Idle position.
Turn Fine Amperage control to
100.
1860 rpm
(Power/Idle)
2

3000 rpm
(Weld)

1

Carburetor

2

Throttle Solenoid

Power/Idle Speed Adjustment
3

Power/Idle Speed Rod

4

Lock Nut

5

Adjustment Nut

Loosen lock nut and rotate adjustment nut until engine runs at power/idle speed. Tighten lock nut.
Weld Speed Adjustment
Place Engine Control switch in Run
position.

Rear View

6

Lock Nut

Loosen nut.
7

1

Hex Swivel

Turn swivel until engine runs at
weld speed. Tighten lock nut.

5

Weld Speed Governor Spring

9

Power/Idle Speed Governor
Spring

If a spring becomes loose or disconnected, reattach as shown.

9

4

8

3
2

6

8

7

Top View

Tools Needed:

3/8 in,
8, 11 mm

Miller Legend

ST-116 049-C

TM-428 Page 39

8-6. Overload Protection
Stop engine.
1

Circuit Breaker CB4 (Internal
– Not Shown)

CB4 protects the unit from overload due to an obstructed throttle
solenoid. If CB4 opens, engine
speed drops to power/idle rpm for
about 10 seconds before automatically resetting.
If CB4 continues to open, check
throttle solenoid TS1 and throttle
linkage.
2

Fuse F1 (See Parts List For
Rating)

F1 protects the exciter excitation
winding from overload.
2

Replace open fuse and reinstall
panel before operating unit.
If F1 continues to open, check integrated rectifier SR2 and rotor.

Tools Needed:

3/8 in
ST-152 264-A

8-7. Inspecting And Cleaning Optional Spark Arrestor
Stop engine and allow to cool.
1

Spark Arrestor Screen

Clean and inspect screen. Replace spark arrestor if screen wires
are broken or missing.

1

Tools Needed:
1/4 in

ST-140 091-E / ST-801 206 / Ref. ST-168 046

TM-428 Page 40

Miller Legend

SECTION 9 – 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 factory for actual circuit, if needed.

The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:
1
2
3
4

Know unit Model and Serial or Style Number.
Use this list to find diagram number.
Include your FAX number or mailing address with your request.
FAX Technical Publications Department at 414-735-4011 or call 414-735-4356.

Model
Miller Legend Without Remote Control

Serial Or Style Number

Circuit
Diagram

Wiring
Diagram

Main Reason
For Change

JH242114 thru JH300533

SC-114 477-A

D-117 651♦♦

JH300534 thru JJ420470

C-117 626-B♦♦

D-123 101♦♦

Changed PC1 and S1, added D5

JJ420471 thru JK713331

C-123 087-B♦♦

D-130 651-A♦♦

Added D6

JK713332 thru KA780043

SC-130 929♦♦

D-130 651-A♦♦

Removed S1

KA780044 thru KA870083

C-135 624♦♦

D-135 628♦♦

Removed F2

KA870084 thru KD346697

C-137 000-A♦♦

D-136 855-D♦♦

Added S1

KD346698 thru KD438828

C-157 770♦♦

D-157 767-A♦♦

Added PC4, PC5

KD438829 thru KD548029

C-162 148♦♦

D-162 146♦♦

Added stator lead 33

KD548030 thru KE604175

C-166 823♦♦

D-166 822♦♦

Hourmeter standard

KE604176 thru KE629033

C-167 423♦♦

D-167 422♦♦

Changed PC2

KE629034 and following

SC-168 053-A

SD-168 051-B

Added CB5, CB7, D8, GFCI

JH242114 thru JH300533

SC-115 947-A

JH300534 thru JJ420470

C-118 207-A♦♦

Changed PC1 and S1, added D5

JJ420471 thru JK713331

C-123 088-B♦♦

Added D6

JK713332 thru KA780043

C-130 928♦♦

Removed S1

KA780044 thru KA870083

C-135 801♦♦

Removed F2

KA870084 thru KD346697

C-137 003-B♦♦

Added S1

KD346698 thru KD438828

C-157 764♦♦

Added PC4, PC5

KD438829 thru KE604175

C-162 147♦♦

Added stator lead 33

KE604176 thru KE629033

C-167 402♦♦

Hourmeter standard,
changed PC2

KE629034 and following

SC-168 054-A

Added CB5, CB7, D8, GFCI

Circuit Board PC1

JH242114 thru JH300533

SB-113 710

Circuit Board PC2

JH242114 thru KE604175

B-049 506-C♦♦

KE604176 and following

SB-160 891

JH242114 thru KA840709

B-115 891-A♦♦

KA840710 and following

SB-136 249

Circuit Board PC4

KD346698 and following

SA-148 024-A

Circuit Board PC5♦

KD346698 and following

SB-156 027

Miller Legend With Remote Control

Circuit Board PC3♦

♦ Optional
Miller Legend

♦♦ Not included in this manual
TM-428 Page 41

SC-114 477-A

Figure 9-1. Circuit Diagram For Miller Legend Without Remote Control
Effective With Serial No. JH242114 Thru JH300533
TM-428 Page 42

Miller Legend

SC-168 053-A

Figure 9-2. Circuit Diagram For Miller Legend Without Remote Control
Effective With Serial No. KE629034 And Following
Miller Legend

TM-428 Page 43

Coat terminals with dielectric grade, nonconductive,
electric grease (MILLER Part No. 146 557) or equivalent.

Figure 9-3. Wiring Diagram For Miller Legend Without Remote Control
Effective With Serial No. KE629034 And Following
TM-428 Page 44

Miller Legend

SD-168 051-B

Miller Legend

TM-428 Page 45

SC-115 947-A

Figure 9-4. Circuit Diagram For Miller Legend With Remote Control
Effective With Serial No. JH242114 Thru JH300533
TM-428 Page 46

Miller Legend

SC-168 054-A

Figure 9-5. Circuit Diagram For Miller Legend With Remote Control
Effective With Serial No. KE629034 And Following
Miller Legend

TM-428 Page 47

SB-113 710

Figure 9-6. Circuit Diagram For Idle Control Board PC1
Effective With Serial No. JH242114 Thru JH300533

SB-160 891

Figure 9-7. Circuit Diagram For Voltage Regulator Board PC2
Effective With Serial No. KE604176 And Following
TM-428 Page 48

Miller Legend

OUTPUT

POSITIVE
SUPPLY+

SB-136 249

Figure 9-8. Circuit Diagram For Optional Remote Control Board PC3
Effective With Serial No. KA840710 And Following

SB-148 024-A

Figure 9-9. Circuit Diagram For HF Filter Board PC4
Effective With Serial No. KD346698 And Following
Miller Legend

TM-428 Page 49

SB-156 027

Figure 9-10. Circuit Diagram For Optional Capacitor Board PC5
Effective With Serial No. KD346698 And Following

TM-428 Page 50

Miller Legend

February 1996
Form: TM-428
Effective With Serial No. JH242114

SECTION 10 – PARTS LIST

Miller Legend
(Formerly The Legend AEAD-200LE)
CC AC/DC Welding Generator For SMAW, GMAW, GTAW Welding

Miller Legend

TM-428 Page 51

TM-428 Page 52

Miller Legend

42

43

Figure 10-3

44

1

39

41

2

38

40

45 46

Figure 10-6

47

Figure 10-5

48

3
4

49

5

6

51

9

50

8

37

11

36

12
13
14

35

17
15 16

34
Figure 10-2

18

Figure 10-1. Main Assembly

10

7

33

20
21

32

19

22

23

29

31

30

28

27

24 25
26

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 10-1. Main Assembly
. . . 1 . . . . . . . . . . . ++042 132 . . . REMOTE CONTROL, (Figure 10-6) (Prior to JK713332) . . . . . . . . . . . . . .
. . . 1 . . . . . . . . . . . ++042 383 . . . REMOTE CONTROL, (Figure 10-6) (Eff w/JK713332) . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . Figure 10-5 . . . CONTROL PANEL, w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 113 302 . . . UPRIGHT, base (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 129 384 . . . UPRIGHT, base (Eff w/KA780148 thru KA892304) . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 136 057 . . . UPRIGHT, base (Eff w/KA892305 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . 107 342 . . . SEAL, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . 113 303 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . +113 304 . . . COVER, top (Prior to JJ365634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . +114 557 . . . COVER, top (Eff w/JJ365634 thru KF812088) . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . +173 209 . . . COVER, top (Eff w/KF812089) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 120 304 . . . BLANK, snap-in nyl .250mtg hole (Eff w/JJ365634 thru KB133271) . . . . .
. . . . . . . . . . . . . . . . . . . . 143 397 . . . BLANK, snap-in nyl .312mtg hole (Eff w/KB133272 thru KF812088) . . . .
. . . 7 . . . . . . . . . . . . . . 108 487 . . . LABEL, warning falling equipment etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . 113 439 . . . PANEL, rear lower (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . 128 789 . . . PANEL, rear lower (Eff w/KA780148 thru KA892304) . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . 136 059 . . . PANEL, rear lower (Eff w/KA892305 and on) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . 095 970 . . . STRIP, nprn wsl eng firewall 18 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . 088 731 . . . BUSHING, snap-in nyl .375 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . PLG5 . . . . . . . . . . . . . . . HOUSING, (part of engine wiring harness)
. . . . . . . . . . . . . . . . . . . . 113 248 . . . TANK, fuel (Prior to KA780148) (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 015 603 . . . . . CAP, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 107 345 . . . . . NECK, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113 685 . . . . . TUBE, pick up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 010 863 . . . CLAMP, hose 2 1/16-3 clamp dia (Prior to KA780148) . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 107 346 . . . HOSE, fuel tank (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 107 324 . . . BRACKET, support pipe filler (Prior to KA780148) . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 107 343 . . . GROMMET, rubber neck filler fuel (Prior to KA780148) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113 486 . . . COVER, fuel tank (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113 392 . . . HOLD DOWN, fuel tank (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113 294 . . . SUPPORT, center mtg engine (Prior to KA780148) . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . 147 601 . . . CAP, tank screw-on w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 130 123 . . . TANK, fuel 7.5gal (Eff w/KA780148 thru KG037343) . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 177 606 . . . TANK, fuel 7.5gal (Eff w/KG037344 and on) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . 145 976 . . . HOSE, nprn SAE .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . 084 173 . . . CLAMP, hose .460–.545clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . 066 113 . . . FILTER, fuel inline .250 (included w/engine) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, hose .460–.545clp dia (included w/engine) . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . HOSE, nprn SAE .250 ID (included w/engine) (order by ft) . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 135 627 . . . ENGINE, gas elect start (Prior to KG037344) (consisting of) . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . 178 479 . . . ENGINE, gas elect start (Eff w/KG037344) (consisting of) . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113 251 . . . . . FITTING, pipe brs cap .375NPT (Prior to KF933389) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113 250 . . . . . FITTING, pipe galv nipple L .375NPT (Prior to KF933389) . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . 165 271 . . . . . VALVE, oil drain (Eff w/KF933389) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 107 297 . . . . . MUFFLER, exhaust engine (Prior to KF926822) . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 164 353 . . . . . MUFFLER, exhaust (Eff w/KF926822) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . 106 977 . . . . . SOLENOID, 12VDC 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 113 563 . . . . . BRACKET, mtg solenoid (Prior to JK595850) . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . 128 534 . . . . . BRACKET, mtg solenoid(Eff w/JK595850) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 128 869 . . . . . LINKAGE KIT, (Prior to JJ404117) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 128 431 . . . . . SWIVEL, in-line .250-28 (Eff w/JJ404117) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . 128 533 . . . . . LINK, throttle (Eff w/JJ404117) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . 064 646 . . . . . SPRING, high speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 137 046 . . . TUNE-UP & FILTER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 064 617 . . . . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 065 251 . . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 121 652 . . . . . FILTER/CLAMPS, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 065 709 . . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miller Legend

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TM-428 Page 53

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 10-1. Main Assembly (Continued)
. . . 27 . . . . . . . . . . . . . . 107 308 . . . HOLD DOWN, bat (Prior to KB113874) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 146 697 . . . HOLD DOWN, bat (Eff w/KB113874 thru KF959176) . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . 165 631 . . . HOLD DOWN, bat (Eff w/KF959177 and on) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 010 493 . . . BUSHING, snap-in nyl .625 ID x .875mtg hole (Prior to KA780148) . . . . .
. . . 28 . . . . . . . . . . . . . . 165 630 . . . BOLT, J stl .250–20 x 6.125 (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . 168 385 . . . LABEL, warning battery explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 115 511 . . . BRACKET, support cover (Prior to KF812089) . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 107 270 . . . DOOR, access battery (Prior to KF959177) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . 175 887 . . . DOOR, access battery (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 088 577 . . . CABLE, bat pos (Prior to KF959177) (consisting of) . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . 167 731 . . . CABLE, bat pos (Eff w/KF959177) (included w/engine) (consisting of) . .
. . . . . . . . . . . . . . . . . . . . 071 970 . . . . . COVER, cable bat post red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . BAT . . . . 071 678 . . . BATTERY, stor 12V (Prior to KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . BAT . . . . 168 037 . . . BATTERY, stor 12V (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 114 923 . . . BOOT, insulator term post red (Prior to KA780148) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 135 571 . . . BOOT, insulator term post red ( Eff w/KA780148 thru KC220663) . . . . . .
. . . . . . . . . . . . . . . . . . . . 108 081 . . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 020 279 . . . CLAMP, stl cushion .750 dia x .281mtg hole (Eff w/KA780148) . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 107 753 . . . CABLE, bat neg (Prior to KA780148) (consisting of) . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . 023 641 . . . CABLE, bat neg (Eff w/KA780148 thru KE668694) (consisting of) . . . . . .
. . . 33 . . . . . . . . . . . . . . 167 730 . . . CABLE, bat neg (Eff w/KE668695) (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 071 971 . . . . . COVER, cable bat post blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . Figure 10-2 . . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 113 298 . . . BASE, (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 132 195 . . . BASE, (Eff w/KA780148 thru KB113873) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . 146 710 . . . BASE, (Eff w/KB113874 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . 134 792 . . . LABEL, warning general precautionary engine etc . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . 057 360 . . . BLANK, snap-in nyl 1.375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . DC-Z . . . . 113 450 . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . AC-Z . . . . 113 451 . . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . SR1 . . . . 142 503 . . . RECTIFIER, si 1ph 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . 113 562 . . . BRACKET, mtg resistor (Prior to JK559100) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . 126 072 . . . BRACKET, mtg-resistor (Eff w/JK559100) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . . 114 544 . . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . Figure 10-3 . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . CT1 . . . . 105 370 . . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . . 012 571 . . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . *083 596 . . . FUSE, mintr cer 12A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . R2,4 . . . . 008 951 . . . RESISTOR, WW adj 180W 12 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . R3,VR1 . . . 046 819 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . RC5 . . . . 116 045 . . . HOUSING PLUG & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 113 633 . . . . . CONNECTOR, rect univ 084 pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . . 109 994 . . . LABEL, warning engine fuel can cause fire . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . . . . . 013 367 . . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 135 475 . . . KIT, label (Prior to KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 176 908 . . . KIT, label (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
++Optional Parts
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-428 Page 54

Miller Legend

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 10-2. Generator (Figure 10-1 Item 34)
. . . 1 . . . . . . . . . . . 013 367
. . . 2 . . . . . . . . . . . 115 500
. . . 2 . . . . . . . . . . . 134 092
. . . 2 . . . . . . . . . . . 176 891
. . . 3 . . . . . . . . . . +113 410
. . . 4 . . . . . . . . . . . 153 297
. . . 5 . . . . . . . . . . . 143 220
. . . 6 . . . . . . . . . . . 165 756
. . . 6 . . . . . . . . . . . 162 138
. . . 6 . . . . . . . . . . . 165 755
. . . 6 . . . . . . . . . . . 162 141
. . . 7 . . . . . . . . . . . 017 702
. . . . . . . . . . . . . . . . . 003 455
. . . 8 . . . . . . . . . . . 021 934
. . . 8 . . . . . . . . . . . 134 981
. . . 9 . . . . . . . . . . . 008 917
. . . 10 . . . . . . . . . . . 049 286
. . . 11 . . . . . . . . . . . 017 624
. . . 12 . . . . . . . . . . . 053 390
. . . 13 . . . . . . . . . . . 024 617
. . . . . . . . . . . . . . . . . 602 348
. . . 14 . . . SR2 . . . 035 704
. . . 15 . . . . . . . . . . . 007 250
. . . 16 . . . . . . . . . . . 047 878
. . . 17 . . . . . . . . . . . 161 306
. . . 18 . . . . . . . . . . *126 984
. . . 19 . . . . . . . . . . . 005 614

. . LABEL, warning fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, engine maintenance Onan (Prior to KA780148) . . . . . . . . . . . . . . . . . .
. . LABEL, engine maintenance Onan P218 (Eff w/KA780148 thru KF959176) .
. . LABEL, engine maintenance Onan P218 (Eff w/KF959177 and on) . . . . . . . . .
. . GUARD, fan gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, gen 60Hz (Prior to KD438829) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, gen 60Hz (Eff w/KD438829) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, gen 50Hz (Prior to KD438829) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, gen 50Hz (Eff w/KD438829) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KEY, woodruff .250 x .750 SAE No. 91 (part of engine) (Prior to KA780148) .
. . ADAPTER, fan rotor (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, fan rotor (Eff w/KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat stl .343 ID x 2 (part of engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR ASSEMBLY, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball rdl sgl row 1.37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining ext 1.272 shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KEY, stl .250 x .250 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH w/SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3

7

8
11

12

6

1

2

3

13

9

10

4
5
14
19
18

15
16

17
ST-115 942-F

Figure 10-2. Generator
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Miller Legend

TM-428 Page 55

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 10-3. Panel, Front w/Components (Figure 10-1 Item 43)
. . . 1 . . . RC1,2 . . . 604 176 . . .
. . . . . . . . . . . . . . . . . . . . 073 690 . . .
. . . 1 . . . RC1,2 . . . 167 657 . . .
. . . 2 . . . CB1,2 . . . . 115 427 . . .
. . . 2 . . . CB5,7 . . . . 168 057 . . .
. . . 3 . . . . . . . . . . . . . . 113 315 . . .
. . . 3 . . . . . . . . . . . . . . 130 352 . . .
. . . 3 . . . . . . . . . . . . . . 143 383 . . .
. . . 3 . . . . . . . . . . . . . . 170 554 . . .
. . . 4 . . . . . S5 . . . . . 005 563 . . .
. . . 5 . . . . . R1 . . . . . 081 712 . . .
. . . 6 . . . . . S4 . . ++011 609 . . .
. . . 6 . . . . . S4 . . . ++011 611 . . .
. . . 7 . . . . RC7 . . . . 035 523 . . .

RECEPTACLE, str dx grd 2P3W 15A 125V (Prior to KE629034) . . . . . . .
PLUG, str grd armd 2P3W 15A 125V P&S 5266 DF
RECEPTACLE, str dx grd 2P3W 15A 125V (Eff w/KE629034) . . . . . . . . .
CIRCUIT BREAKER, man reset 1P 25A 250VAC (Prior to KE629034) . .
CIRCUIT BREAKER, man reset 1P 20A 250VAC (Eff w/KE629034) . . . .
PANEL, front (Prior to JK713332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front (Eff w/JK713332 thru KB133271) . . . . . . . . . . . . . . . . . . . . . .
PANEL, front (Eff w/KB133272 thru KF790319) . . . . . . . . . . . . . . . . . . . . . .
PANEL, front (Eff w/KF790320 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, selector (Figure 10-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RHEOSTAT, WW 100W 30 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, tgl SPDT 15A 125VAC (Prior to JK713332) . . . . . . . . . . . . . . . . .
SWITCH, tgl DPDT 15A 125V (Eff w/JK713332) . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, circ MS/MET 5skt sz 16S rect MS-3102A-16S-8S
Amphenol (Prior to JK713332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2
2
2
1
1
1
1
1
1
1
1
1

Figure 10-4
4

3

2

5

6

7

1

8
9

10

35
34
14

11
12

33

15

13
32
31
30
29

28

16

27
18
17
26
25

20

24
21

23

19

21
22

ST-115 943-J

Figure 10-3. Panel, Front w/Components
TM-428 Page 56

Miller Legend

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 10-3. Panel, Front w/Components (Figure 10-1 Item 43)
(Continued)
. . . . . . . . . . . . . . . . . . . . 039 273 . . . CONNECTOR, circ MS/MET 5 pin sz 16S MS-3106A-16S-8P Amphenol
. . . . . . . . . . . . . . . . . . . . 039 685 . . . CONNECTOR, circ MS/MET clamp str rlf sz 16-16S AN-3057-8 Amphenol
. . . 7 . . . . RC7 . ++086 022 . . . CONNECTOR, circ MS/MET 14skt sz 20 MS-3102A-20-27S
(Eff w/JK713332 thru KD344393) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 109 766 . . . CONNECTOR, circ 14 pin MS sz 20 Amphenol 97-4106A-20-27P
. . . . . . . . . . . . . . . . . . . . 109 770 . . . CONNECTOR, circ MS pin push-in 16-22ga
. . . . . . . . . . . . . . . . . . . . 039 734 . . . CONNECTOR, circ MS/MET clamp str rlf sz 20-22S
Amphenol AN-3057-12
. . . 7 . . . . PC5 . . . . 156 025 . . . CIRCUIT CARD, connector/receptacle (Eff w/KD344394) . . . . . . . . . . . . . 1
. . . . . . . . . . C7-11 . ++097 749 . . . CAPACITOR, (Eff w/JK713332 thru KD344393) . . . . . . . . . . . . . . . . . . . . . . 5
. . . 8 . . . . . S1 . . . . . 011 622 . . . SWITCH, tgl 3PDT 15A 125VAC (Prior to JK713332) . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S1 . . . . . 011 611 . . . SWITCH, tgl DPDT 15A 125V (Eff w/JK713332) . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . S2 . . . . . 172 070 . . . SWITCH, ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB3 . . . . 083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 601 836 . . . NUT, brs hex jam hvy .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 12 . . . . . . . . . . . . . . 010 915 . . . WASHER, flat brs .250 ID x .625 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . 083 030 . . . STUD, brs grd .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . ♦042 130 . . . METER KIT, (Prior to KD548030) (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . HM . . . . . 032 936 . . . . . METER, hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 145 247 . . . METER, hour 12-24VDC (Eff w/KD548030) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . CB1,2 . . . . 144 474 . . . CIRCUIT BREAKER, man reset 1P 25A 250VAC (Eff w/KE629034) . . . . 2
. . . 16 . . . . RC3 . . . . 604 103 . . . RECEPTACLE, str dx grd 2P3W 15A 250V (Prior to JH300534) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 025 234 . . . PLUG, str grd 2P3W 15A 250V Leviton 5443
. . . 16 . . . . RC3 . . . . 129 067 . . . RECEPTACLE, twlk grd 3P4W 30A 125/250V (Eff w/JH300534) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 088 898 . . . PLUG, twlk grd 3P4W 30A 125/250V
. . . 17 . . . . RC4 . . . . 034 952 . . . RECEPTACLE, str 3P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 073 690 . . . PLUG, str grd armd 2P3W 15A 125V P&S 5266 DF
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model & serial number) . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . POS . . . . 039 047 . . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . NEG . . . . 039 046 . . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 099 255 . . . TERMINAL, pwr output neutral (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . 601 976 . . . . . SCREW, cap stl hex hd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 039 049 . . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 039 045 . . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 039 040 . . . . . TERMINAL BOARD, neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . 601 880 . . . . . NUT, stl hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 039 044 . . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 601 879 . . . . . NUT, stl hex full fnsh .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . 073 756 . . . STAND-OFF, No. 6-32 x .625 lg x .250 hex (Eff w/KD344394) . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 153 501 . . . HOUSING PLUG & SOCKETS, (Eff w/KD344394) (consisting of) . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 147 995 . . . . . CONNECTOR, rect univ 039skt 22-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 28 . . . . . C6 . . . . . 115 109 . . . CAPACITOR, (Prior to KD344394) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . PC4 . . . . 148 021 . . . CIRCUIT CARD, filter HF (Eff w/KD344394) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 111 584 . . . CONTROL, push-pull (Prior to JH283238) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 116 813 . . . CONTROL, push-pull (Eff w/JH283238) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . 119 014 . . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . ++108 864 . . . CAP, dust connector 9760-16 (Prior to JK713332) . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . ++109 993 . . . CAP, dust connector 9760-20 (Eff w/JK713332) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 097 924 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 010 647 . . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . ++021 385 . . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 115 493 . . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
++Part of Remote Control Option
♦Effective w/KD548030 Optional Meter Kit became Standard Equipment.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Miller Legend

TM-428 Page 57

Item
No.

Part
No.

Description

005 563
...
...
...
...
...
...
...
...
...
...
...
...
...

1 ........
2 ........
3 ........
4 ........
5 ........
6 ........
7 ........
8 ........
9 ........
10 . . . . . . . .
11 . . . . . . . .
12 . . . . . . . .
13 . . . . . . . .

005 562
005 561
005 564
605 276
005 559
005 560
008 485
005 566
011 644
052 405
052 404
005 557
005 558

Quantity

Figure 10-4. Switch, Selector (Figure 10-3 Item 4)
..
..
..
..
..
..
..
..
..
..
..
..
..

BRACKET, mtg-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHAFT, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, screw switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, cap stl hex hd .250-20 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT BOARD, movable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT, switch movable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER, contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT BOARD, stationary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT, stationary switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT, movable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRING, selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
1
1
7
1
1
1
1

10
9

8

11

7
6
5
4

12
3
2
1

13
ST-097 264-A

Figure 10-4. Switch, Selector
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-428 Page 58

Miller Legend

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 10-5. Control Panel, w/Components (Figure 10-1 Item 2)
. . . 1 . . . . . 1T . . . . .
. . . 1 . . . . . 1T . . . . .
... 2 ..............
... 2 ..............
... 3 ..............
. . . 4 . . . . PC2 . . . .
. . . 4 . . . . PC2 . . . .
. . . . . . . . . . PLG1 . . . .
....................
. . . 5 . . . . CR4 . . . .
. . . 6 . . . . CR3 . . . .
. . . 7 . . . . CR2 . . . .
. . . 8 . . . . CB4 . . . .
. . . 9 . . . . PC1 . . . .
. . . 9 . . . . PC1 . . . .
. . . 10 . . . . . D4 . . . . .
. . . 10 . . . . D4,5 . . . .
. . . 11 . . . . . T1 . . . . .
. . . 11 . . . . . T1 . . . . .
. . . 12 . . . . . . . . . . . . . .
. . . . . . . . . . . D6 . . . . .

038 601 . . . BLOCK, term 30A 9P (Prior to JK713332) . . . . . . . . . . . . . . . . . . . . . . . . . . .
130 648 . . . BLOCK, term 30A 10P (Eff w/JK713332) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 682 . . . BRACKET, mtg components (Prior to JK713332) . . . . . . . . . . . . . . . . . . . . .
130 649 . . . BRACKET, mtg components (Eff w/JK713332) . . . . . . . . . . . . . . . . . . . . . . .
083 147 . . . GROMMET, scr No.8/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
049 404 . . . CIRCUIT CARD, regulator 115V (Prior to KE604176) . . . . . . . . . . . . . . . . .
160 888 . . . CIRCUIT CARD, voltage regulator (Eff w/KE604176) (Figure 10-7) . . . . .
168 071 . . . CONNECTOR & SOCKETS, (Eff w/KE604176) (consisting of) . . . . . . . . .
114 066 . . . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 247 . . . RELAY, encl 12VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
044 588 . . . RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
173 069 . . . RELAY, encl 12VDC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
045 061 . . . CIRCUIT BREAKER, auto reset 24VDC 7A . . . . . . . . . . . . . . . . . . . . . . . . .
113 492 . . . CIRCUIT CARD, weld/idle (Prior to JH300534) . . . . . . . . . . . . . . . . . . . . . .
142 725 . . . MODULE, pull to weld/power delay (Eff w/JH300534) . . . . . . . . . . . . . . . . .
059 389 . . . DIODE, rect 3A 1000V SP (Prior to JH300534) . . . . . . . . . . . . . . . . . . . . . .
059 389 . . . DIODE, rect 3A 1000V SP (Eff w/JH300534) . . . . . . . . . . . . . . . . . . . . . . . .
116 083 . . . TRANSFORMER, control (Prior to KE604176) . . . . . . . . . . . . . . . . . . . . . . .
167 404 . . . TRANSFORMER, control (Eff w/KE604176) . . . . . . . . . . . . . . . . . . . . . . . . .
038 620 . . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117 566 . . . DIODE, rect 6A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
4
1
1
1
9
1
1
1
1
1
1
1
2
1
1
1
1

1
2

3
Figure 10-7
4

12
11

10

7

5
6

9
8

ST-114 309-B

Figure 10-5. Control Panel, w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Miller Legend

TM-428 Page 59

Item
No.

Dia.
Mkgs.

Part
No.

Description

+042 132
+042 383
. . . 1 . . . . PC3 . . . .
... 2 ..............
... 3 ..............
... 3 ..............
. . . 4 . . . . CR5 . . . .
... 5 ..............
. . . 6 . . . . . C5 . . . . .
. . . 7 . . . . . 2T . . . . .
... 8 ..............
. . . 9 . . . . PLG6 . . . .
....................

Quantity

Figure 10-6. Remote Control, Option (Figure 10-1 Item 1)

136 246 . . . CIRCUIT CARD ASSEMBLY, remote control . . . . . . . . . . . . . . . . . . . . . . . .
110 375 . . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116 086 . . . BRACKET, mtg remote control (Prior to JK563388) . . . . . . . . . . . . . . . . . . .
125 873 . . . BRACKET, mtg remote control (Eff w/JK563388) . . . . . . . . . . . . . . . . . . . . .
052 603 . . . RELAY, encl 110VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
007 532 . . . CLAMP, capacitor 1.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
059 887 . . . CAPACITOR, polyp met film 10uf 220V . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116 005 . . . BLOCK, term 10A 7P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 023 . . . LINK, jumper term blk 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 091 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
113 746 . . . . . TERMINAL, female 1skt 18-24W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
4
1
1
1
1
1
1
4
1
10

3
2
1

9
8
7

6

5

4
SB-116 028

Figure 10-6. Remote Control, Option
+See Figure 10-3 for additional parts not listed
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-428 Page 60

Miller Legend

Dia.
Mkgs.

Part
No.

PC2

160 888

. . . . . . A50 . . . . . . . 165 411
. . . . . . . C1 . . . . . . 003 530
. . . . . . C50 . . . . . . . 119 199
. . . . . . C51 . . . . . . 053 992
. . . . . . C52 . . . . . . 000 348
. . . . . . C53 . . . . . . 005 023
. . . . . . C54 . . . . . . 072 935
. . . . . . C55 . . . . . . 137 463
. . . . . . C56 . . . . . . . 072 113
. . . . . . C57 . . . . . . 028 292
. . . . . . D50 . . . . . . 028 351
. . . . . . D51 . . . . . . 049 641
. . . . . D52-54 . . . . 026 202
. . . . . D55-58 . . . . 070 250
. . . . . . D59 . . . . . . 030 529
. . . . . . Q50 . . . . . 039 355
. . . . . Q51,52 . . . . 037 200
. . . . . Q53,54 . . . . 049 642
. . . . . . R50 . . . . . . 094 447
. . . . . . R51 . . . . . . 044 789
. . . . . . R52 . . . . . . 035 829
. . . R53,54,65 . . . 072 559
. . . . . . R55 . . . . . . . 115 530
. . . . . R56,64 . . . . 000 885
. . . . . R57,62 . . . . 028 285
. . . . . R58,63 . . . . 035 823
. . . . . . R59 . . . . . . 072 559
. . . . . . R60 . . . . . . 074 026
. . . . . . R61 . . . . . . 138 301
. . . . . . R66 . . . . . . 093 030
. . . . . . R67 . . . . . . 093 032
. . . . . . R68 . . . . . . 108 437
. . . . . . R69 . . . . . . 049 439
. . . . . . R70 . . . . . . 074 099
. . . . . . R71 . . . . . . 030 707
. . . . . . RC1 . . . . . 160 892
. . . . . . VR50 . . . . . 083 772

Description

Quantity

Figure 10-7. Circuit Card, Voltage Regulator (Figure 10-5 Item 4)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

IC, linear 2904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, cer mono 1uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polye met film 1uf 50V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, cer disc .001uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, tantlm .47uf 35V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, tantlm 2.2uf 20V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 33uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polye met film .22uf 100VDC . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, tantlm 4.7uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, cer disc .005uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, sig 200mA 75V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, zener 27V 1W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, rect 3A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, rect 22A 600V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSISTOR, ujt 15mA 40V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSISTOR, NPN 200mA 40V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THYRISTOR, SCR 8A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 681K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 1.5K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 22.1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 2.67K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, C .5W 100 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 100 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 22.1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, C .25W 150 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POTENTIOMETER, cermet trmr 1/T .5W 25K ohm . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 15K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 26.7K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, MF .25W 4.75K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, C 2W 47K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, C 1W 150 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, C 1W 47 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, rect 9 pin 3 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IC, rgltr 7815 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
1
1
1
1
1
1
3
4
1
1
2
2
1
1
1
3
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1

SA-160 889

Figure 10-7. Circuit Card, Voltage Regulator PC2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Miller Legend

TM-428 Page 61

Notes

Notes



---

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