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Page Count: 68

February 1996 Form: TM-428

Effective With Serial No. JH242114

TECHNICAL MANUAL

Service And Parts

cover_tm 4/95 – ST-140 091-E PRINTED IN USA

 1996 MILLER Electric Mfg. Co.

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

Auxiliary Power

Rating Fuel Capacity Engine

CC/AC 35

– 225 A

225 A, 25 V

100% Duty

Cycle 80 Single-Phase,

5 kVA/kW

, 42/21 A,

120/240 V AC, 60 Hz

And

7 5 gal (28 L) T

ank

Onan P218 Air-Cooled,

Two

Cylinder, Four

Cycle,

CC/DC

25 – 200 A

200 A, 25 V

100% Duty

Cycle 72

And

Single-Phase,

1 kVA/kW

, 9 A,

15 V AC, 100 Hz

7.5 gal (28 L) T

ank

wo-

er,

our-

Gasoline Engine

OM-428N 1/96 – SPM-428C 6/94

HCALL:

Miller Customer Service

Department at

414-735-4505

WHO DO I CONTACT FOR HELP?

HFAX:

800-637-2348

(in USA),

414-735-4136 (outside USA)

HWRITE:

Miller Electric Mfg. Co.

.O. Box 1079

Appleton, WI 54912 USA

Always provide Model Name and Serial or Style Number

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING 1.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Servicing Hazards 1.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. EMF Information 2.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 3.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Installing

elding Generator 3.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dimensions,

eights, And Operating Angles 3.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Fuel Consumption 4.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Engine Prestart Checks 4.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Connecting The Battery 5.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Connecting To Weld Output Terminals 5.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Selecting

eld Cable Sizes 6.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Remote 14 Receptacle RC1 Information 6.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION

3 – OPERA

TING WELDING GENERATOR 7.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Front Panel Controls 7.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Remote Control (Optional) 8.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Duty Cycle 8.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Volt-Ampere Curves 9.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION

4 – OPERA

TING AUXILIAR

Y EQUIPMENT

10.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. 100 Hz Auxiliary Power Receptacle And Circuit Breaker 10.

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. AC Auxiliary Power Curve 10.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. 60 Hz Auxiliary Power Receptacles And Circuit Breakers 11.

. . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – THEOR

Y OF OPERA

TION 12.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – TROUBLESHOOTING 15.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Tables 15.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Troubleshooting Circuit Diagram For Welding Generator 18.

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control 20.

6-4. Waveforms For Sections 6-2 And 6-3 22.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Idle Control Board/Module PC1 Testing Information 23.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Troubleshooting Flowcharts For Idle Control Board/Module PC1 24.

. . . . . . . . . . . . . . . . . . . . .

6-7. Voltage Regulator Board PC2 Testing Information Prior To Serial No. KE604176 26.

. . . . . . .

6-8. Voltage Regulator Board PC2 Test Point Values Prior To Serial No. KE604176 26.

. . . . . . . .

6-9. Voltage Regulator Board PC2 Testing Information Effective With Serial No. KE604176 27.

. .

6-10. Voltage Regulator Board PC2 Test Point Values Effective With Serial No. KE604176 27.

. . .

6-11. Optional Remote Control Board PC3 Testing Information 28.

. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-12. Optional Remote Control Board PC3 Test Point Values 28.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-13. Optional Remote Capacitor Board PC5 Testing Information Effective With

Serial No. KD346698 29.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-14. Optional Remote Capacitor Board PC5 Test Point Values Effective With

Serial No. KD346698 29.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-15. Replacing Brushes And Cleaning Slip Rings 30.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-16. Checking Unit Output After Servicing 32.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – DISASSEMBL

Y AND REASSEMBL

Y33.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Disassembly Of Unit 33.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Disassembly Of Generator 34.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – MAINTENANCE 35.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Routine Maintenance 35.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Maintenance Label 36.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Servicing Air Cleaner 37.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Changing Engine Oil, Oil Filter, And Fuel Filter 38.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Adjusting Engine Speed 39.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Overload Protection 40.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Inspecting And Cleaning Optional Spark Arrestor 40.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – ELECTRICAL DIAGRAMS 41.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – PARTS LIST 51.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-428 Page 1

Miller Legend

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.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING

PARTS,

and HOT P

TS hazards. Consult symbols and related instructions below for necessary

actions

to avoid the hazards.

Marks a special safety message.

Means NOTE; not safety related.

1-2. Servicing Hazards

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.

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

ARTS 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

generator components.

Reinstall panels or

guards and close doors when

servicing is finished and before starting engine.

FLYING

PIECES

OF MET

AL 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.

ENGINE FUEL can cause fire or

explosion.

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.

Replace damaged battery

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,

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.

Securely attach components to lifting

equipment.

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.

WARNING

TM-428 Page 2

Miller Legend

HOT PARTS can cause severe burns.

1. Allow

cooling period before servicing.

2. Wear

protective gloves and clothing when working

a hot engine.

ELECTRIC SHOCK HAZARD from

incorrect use of test equipment.

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.

Read instructions for test equipment.

MAGNETIC FIELDS FROM HIGH

CURRENTS can affect pacemaker

operation.

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.

PINCH POINTS can injure.

1. Be careful when working on stator and rotor

assemblies.

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.

3. Use

only genuine MILLER replacement parts.

4. Reinstall injectors and bleed air from fuel system

according to engine manual.

1-3. EMF Information

Considerations

About W

elding And The Ef

fects Of Low

Frequency

Electric

And Magnetic Fields

The

following is a quotation from the

General Conclusions Section

the U.S. Congress, Of

fice of T

echnology 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 of

fer clear science-based advice on strategies to minimize

avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep

cables close together by twisting or taping them.

Arrange cables to one side and away from the operator

Do not coil or drape cables around the body

Keep welding power source and cables as far away as

practical.

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.

TM-428 Page 3

Miller Legend

SECTION 2 – INSTALLATION

2-1. Installing Welding Generator

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

Electrically

bond

generator frame to

vehicle frame by metal-to-metal

contact.

GND/PE

1 Generator Base

Metal V

ehicle Frame

Equipment Grounding

Terminal

Grounding Cable

Use #10 AWG or larger insulated

copper

wire.

YIf unit does not have GFCI

receptacles, use GFCI-pro-

tected

extension cord.

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Movement Airflow Location

Grounding

YDo Not Lift Unit From End

2-2. Dimensions, Weights, And Operating Angles

ADimensions

Height 31-5/8

in (803 mm)

YDo not exceed operating angles while

running

or engine damage will occur

t t it h it ld

Width 18

in (457 mm)

YDo

not move or operate unit where it could

tip.

Depth 45

in (1

143 mm)

BA 16-1/2

in (419 mm)

B 32-3/4

in (832 mm)

25°

C 13/16

in (21 mm) Dia.

25°

Weight

25°

CNet 559

lb (254 kg)

Engine End

Ship 600

lb (272 kg)

TM-428 Page 4

Miller Legend

2-3. Fuel Consumption

SB-115 572

2-4. Engine Prestart Checks

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

Check

all fluids daily

. Engine must

cold and on a level surface.

Engine stops if oil pressure gets

too

low

1/2 in

(13 mm)

Full

TM-428 Page 5

Miller Legend

2-5. Connecting The Battery

Tools

Needed:

+–

3/8, 1/2 in

Connect (–) cable last.

Ref. ST-144 839-F / Ref. ST-168 046 / Ref. S-0756-D

2-6. Connecting To Weld Output Terminals

YUse ONLY one set of termi-

nals at a time. Disconnect

weld

cables from

set of weld

output

terminals not in use.

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

Tools

Needed:

3/4 in

TM-428 Page 6

Miller Legend

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 10 – 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

Weld cable size (A

WG) 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* 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.

DRemote

control circuit common.

CLNH

E 0

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

ST-140 092-B

EFK Chassis

common.

*The remaining sockets are not used.

TM-428 Page 7

Miller Legend

SECTION 3 – OPERATING WELDING GENERATOR

3-1. Front Panel Controls

Ref. ST-168 046

1 Engine

Control Switch S2

Use switch to start engine, select speed,

and stop engine. In Run/Idle position, en-

gine

runs at power/idle rpm at no load, and

weld/power

rpm under weld or 100 Hz auxil

iary

power receptacle load. In Run

position,

engine

runs at weld rpm.

Idle Lock Switch S1

Use switch to lock engine at power/idle

speed (see Table). In Unlock position, En-

gine Control switch and optional Remote

Control

switch determine engine speed.

Engine Choke Control

Use control to change engine air-fuel mix.

To Start: pull out choke and turn Engine

Control switch to Start position. Release

switch and slowly push choke in when en-

gine starts. Do not crank engine while fly-

wheel

is turning.

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).

Ampere Ranges Switch S5

Use

switch to select weld amperage range.

For best arc starts, use lowest amper-

age

range possible.

Fine Amperage Control R1

Use

control to select

weld amperage within

the range selected by the Ampere Ranges

switch.

Control

may be adjusted while weld

ing.

Scale is

for reference only

. W

eld output

would be 88 A DC with control settings as

shown

(50% of 70 to 105 A).

Engine Hour Meter HM

Using Idle Lock Switch

RUN/IDLE

LOCK

UNLOCK

1860 rpm

RUN/IDLE

RUN

LOCKUNLOCK

(Power/Idle)

1860 rpm

(Power/Idle)

No Load:

3000 rpm

Load:

3000 rpm

(Weld)

6 7

(Weld)

TM-428 Page 8

Miller Legend

3-2. Remote Control (Optional)

YWeld output terminals are

energized when Remote

Control switch S4 is in Pan-

el/On

position and engine is

running.

1 Remote

14 Receptacle RC1

Connect

optional remote control

RC1

(see Section 2-8).

ST-140 092-B

Min (70

A DC)

Max (88

A DC)

Adjust Remote Control

Set Range

Set Percentage

Min = 70

A DC

Percentage Of Range = 50%

Max = 88

DC (50% of 70 to 105)

In Example:

Set Switch

3-3. Duty Cycle

SB-115 570

Duty

cycle is the percentage of 10

minutes

that unit can weld at

rated

load

without overheating.

YExceeding duty cycle can

damage unit and void war-

ranty.

Continuous

elding

100% Duty Cycle at 225 Amperes AC

TM-428 Page 9

Miller Legend

3-4. Volt-Ampere Curves

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

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities

the welding generator

. Curves of

other settings fall between the

curves

shown.

TM-428 Page 10

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SECTION 4 – OPERATING AUXILIARY EQUIPMENT

4-1. 100 Hz Auxiliary Power Receptacle And Circuit Breaker

YDo not operate 50/60 Hz or

60 Hz equipment from 100

receptacle.

15 V 9 A 100 Hz AC Recep

tacle RC4

Receptacle supplies single-phase

power at weld speed only. Total

output

available is 1 kV

A/kW.

2 Circuit Breaker CB3

CB3 protects receptacle from

overload.

If CB3 opens, receptacle

does

not work.

Ref. ST-168 046

4-2. AC Auxiliary Power Curve

SB-115 571

TM-428 Page 1

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

Ref. ST-168 046

57812

YIf unit does not have GFCI recep-

tacles, use GFCI-protected exten-

sion

cord.

1 120

V 15 A AC

Duplex Receptacle RC1

120 V 15 A AC Duplex Receptacle RC2

3 240

V 30 A T

wistlock 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 re

ceptacle is 5 kVA/kW. For 60 Hz auxiliary

power,

set controls as shown in table.

120 V 15 A AC Duplex GFCI Recep

tacles GFCI1 And GFCI2 (Optional)

ground fault is detected, the GFCI recep

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 T

est

button

to verify GFCI is working properly.

5 Circuit Breaker CB5

6 Circuit Breaker CB7

CB5 protects RC1 and CB7 protects RC2

from

overload. If CB5 or CB7 opens, the re

ceptacle does not work. Press button to re-

set

breaker

7 Circuit Breaker CB1

8 Circuit Breaker CB2

CB1 and CB2 protect all the 60 Hz recep-

tacles 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 recep-

tacle.

Press button to reset breaker

otal Auxiliary Power Output

Combined output of receptacles limited to

the 5 kV

A/kW output of the generator:

EXAMPLE:

If 10 A is drawn from a 120 V du

plex

receptacle, only 16 A is available at the

240

V receptacle:

(120

V x 10 A) + (240 V x 16 A) = 5.0 kV

A/kW

PANEL

0 100

LOCK UNLOCK

RUN/IDLE RUN/IDLE

PANEL

0 100

For 60 Hz

Auxiliary Power

While W

elding

For 60 Hz

Auxiliary

Power Only

TM-428 Page 12

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1 Engine

Supplies force to turn revolving

fields.

2 Revolving

Fields (Rotor)

Turn

at 1860 rpm maximum for pow

er/idle and 3000 rpm maximum for

weld.

The speed and excitation cur

rent of the field coils determine volt

ages in stator windings.

Stator Windings

Supply power to exciter, auxiliary

power,

and weld circuits.

Fuse F1

Protects exciter excitation winding

from

overload.

Integrated Rectifier SR2

Changes ac output of stator wind-

ings

to dc to supply excitation current

the exciter revolving field.

Control Relay CR5

Energizes

when voltage is present in

exciter stator to disconnect field

flashing circuit.

Idle Module PC1 And Idle Lock

Switch S1

PC1 and S1 control engine speed.

Without

a signal from CT1, PC1 low

ers engine speed to power/idle rpm.

8 Throttle

Solenoid TS1

Increases

engine speed to weld rpm

when

energized.

Current T

ransformer CT1

Senses output from either weld or

100 Hz auxiliary power windings,

and signals PC1 to increase to or

maintain

weld rpm.

10 Control Relays CR2, CR3, CR4

CR2

energizes at weld rpm to supply

power

to throttle solenoid TS1.

CR3 energizes at power/idle rpm to

bypass

fine amperage control R1.

CR4 energizes at power/idle rpm to

provide 50/60 Hz auxiliary power

output.

11 Voltage

Regulator Board PC2

And T

ransformer T1

PC2 monitors 50/60 Hz auxiliary

power

voltage through T1, and main

tains

proper output by adjusting

field

current.

12 Capacitor

Board PC5, Remote

14 Receptacle RC1, Remote

Control Board PC3

PC5

protects unit from high frequen

cy.

RC1

connects remote amperage

and contactor control to unit through

control

board PC3.

SECTION 5 – THEORY OF OPERATION

Voltage

Regulator

Board PC2

Current

Transformer

CT1

Circuit

Breaker

CB3

100 Hz

Auxiliary Power

Receptacle RC4

Fuse

Integrated

Rectifier SR2

Revolving

Fields (Rotor)

Fine

Amperage

Control R1

Remote Control

Switch S4

Remote 14

Panel

Remote

Control Board

PC3

Capacitor Board

PC5

And Remote 14

Receptacle RC1

Engine

Idle Module

Control Relays

CR2, CR3, CR4

Idle Lock

Switch S1

716

♦

13♦

12♦

PC1

CR3

Throttle

Solenoid

TS1

Control

Relay

CR5

♦

Voltage

Regulator 60 Hz Auxiliary

Power

Exciter

Stator Windings

Weld

100 Hz

Auxiliary

Power

TM-428 Page 13

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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.

50/60 Hz Auxiliary Power Re

ceptacles RC1, RC2, And

RC3

Provide connection points and

power

for auxiliary equipment.

16 Circuit Breaker CB3

Protects

100 Hz auxiliary power

ceptacle

RC4 from overload.

17 100 Hz Auxiliary Power Re-

ceptacle RC4

Provides connection point and

power for auxiliary equipment

while

welding.

Fine Amperage Control R1

Adjusts

amperage

within range se

lected by Ampere Ranges switch

S5.

19 Ampere

Ranges Switch S5

Selects coarse range of weld out-

put

from weld stator

20 Reactor AC-Z

Tapped reactor limits weld output

and

provides coarse ranges.

Main Rectifier SR1

Changes ac output from weld

windings

to dc.

Stabilizer DC-Z

Smooths out current to dc weld

output

terminals.

HF Filter Board PC4

Protects unit from high frequency

Positive (+) And Negative (–)

DC W

eld Output T

erminals

Provide dc weld output.

Electrode And W

ork AC Weld

Output T

erminals

Provide ac weld output.

Stabilizer

Main

Rectifier

SR1

Ampere

Ranges

Switch S5

Reactor

AC-Z

DC-Z

HF Filter

Board

PC4

Positive (+)

And

Negative (–) DC

eld Output

Terminals

Transformer

Circuit

Breakers

CB1, CB2,

50/60 Hz

Auxiliary Power

Receptacles

RC1, RC2, RC3

14 15

23 25

Electrode

And

Work AC Weld

Output

Terminals

AC Or DC Control Circuits

Mechanical Coupling

eld Current Circuit

Magnetic Coupling

♦Optional

CR4

CB5, CB7

TM-428 Page 14

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NOTES

TM-428 Page 15

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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 Remedy

No weld output.

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%.

place 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

if necessary (see Section 3-1).

Disconnect

leads 22 and 29 from SCR/integrated rectifier SR2, and check for continuity between leads

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 con

nections. 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 Sec

tion

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.

TM-428 Page 16

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B. 50 Or 60 Hz Auxiliary Power

Trouble Remedy

No auxiliary power output at recep-

tacles RC1, RC2, or RC3.

Run engine at power/idle speed.

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 nec

essary.

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

con

tacts. 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

con

tacts. 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

auxiliary power output at receptacle

RC4. Run

engine at weld speed.

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 17

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D. Engine

Trouble Remedy

Engine will not start.

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

gine Control switch S2 returns to Run

position.

Check

oil

level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual

for

location). S3 should close when engine is running.

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-

tion. Check

oil

level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual

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 Of

f 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

weld

speed.

ait 10 seconds for throttle solenoid circuit breaker CB4 to reset (see Section 8-6).

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

con

tacts. 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

une-up engine according to engine manual.

TM-428 Page 18

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6-2. Troubleshooting Circuit Diagram For Welding Generator

Test

Equipment Needed:

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

34 ohms

35 ohms

2 ohms

R6 thru R17

Less than 1 ohm

R18

Pull: Less than 1 ohm Hold: 16.5 ohms

CR2 energized

Field current

at weld rpm

V14/R17

V15

V16/ V17/

R1 R2

I1 I2

V11,

V12,

V13/R12

V18

V19

R16 R15 R14 R13

Throttle

control relay

control relay CR3

and auxiliary power

control relay CR4

energized at

power/idle rpm

See Section

6-16 for R2 and

R4 adjustment

See Section 6-5

for PC1 data

R18

TM-428 Page 19

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SC-168 053-A

Amperage Readings

a) Tolerance – ±5% unless specified

b) Condition – 70°F (21°C); cold machine

(no warm-up); no load

I1 3

amps dc

1.8 amps dc (R1 at min.)

3.1 amps dc (R1 at max.)

Voltage Readings

a) Tolerance – ±10% unless specified

b) Condition – 70°F (21°C); cold

machine (no warm-up); no load

c) Reference – to circuit common

(lead 33) unless noted

d) 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)

At RC3 at power/idle rpm:

244 volts ac

5% (50 or 60 Hz)

At RC2 at power/idle rpm:

122 volts ac

5% (50 or 60 Hz)

At RC1 at power/idle rpm:

122 volts ac

5% (50 or 60 Hz)

AC input to transformer T1: 122 volts ac

(power/idle rpm), 0 volts ac (weld rpm)

AC output to PC2: 21 volts ac

±5%

AC output to PC2: 21 volts ac

±5%

AC output from Regulator Power

Winding (power/idle rpm)

158 volts ac

±5%

V10

AC output from W

eld 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)

V2/C/D V1/A/B

V9/R9

V10/R8

V7/

V8/

V6/R3

R10

R11

See Sections 6-7

thru 6-9 for PC2 data

See Section 6-4 for

waveforms A thru D

See Section 5 for

PC4 information

TM-428 Page 20

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6-3. Troubleshooting

Circuit Diagram For W

elding Generator W

ith Optional Remote Control

Test

Equipment Needed:

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

34 ohms

35 ohms

2 ohms

R6 thru R17

Less than 1 ohm

CR2 energized

Field current

at weld rpm

Throttle

control relay

control relay CR3

and auxiliary power

control relay CR4

energized at

power/idle rpm

V14/R17

V15

V16/ V17/

R1 R2

I1 I2

1, V12,

V13/R12

V18

V19

R16 R15

R14 R13

Field flashing

disconnect relay CR5

See Section

6-11

for PC3 data

See Section 6-13

for PC5 data

See Section 6-5

for PC1 data

See Section

6-16 for R2 and

R4 adjustment

TM-428 Page 21

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SC-168 054-A

Amperage Readings

a) Tolerance – ±5% unless specified

b) Condition – 70°F (21°C); cold machine

(no warm-up); no load

I1 3

amps dc

1.8 amps dc (R1 at min.)

3.1 amps dc (R1 at max.)

Voltage Readings

a) Tolerance – ±10% unless specified

b) Condition – 70°F (21°C); cold

machine (no warm-up); no load

c) Reference – to circuit common

(lead 33) unless noted

d) 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)

At RC3 at power/idle rpm:

244 volts ac

5% (50 or 60 Hz)

At RC2 at power/idle rpm:

122 volts ac

5% (50 or 60 Hz)

At RC1 at power/idle rpm:

122 volts ac

5% (50 or 60 Hz)

AC input to transformer T1: 122 volts ac

(power/idle rpm), 0 volts ac (weld rpm)

AC output to PC2: 21 volts ac

±5%

AC output to PC2: 21 volts ac

±5%

AC output from Regulator Power

Winding (power/idle rpm)

158 volts ac

±5%

V10

AC output from W

eld 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)

V2/C/D V1/A/B

V9/R9

V10/R8

V7/

V8/

V6/R3

R10

R11

See Section 6-4 for

waveforms A thru D

See Section 5 for

PC4 information

See Sections 6-7

thru 6-9 for PC2 data

TM-428 Page 22

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

Test

Equipment Needed:

aveforms shown are for 60 Hertz models;

waveforms for 50 Hertz models are similar

2 ms 50 V

A. DC Open-Circuit

oltage, Ampere Ranges

Switch S5 In Max Position

2 ms 10 V

B. DC Weld Output, 25 Volts DC, 100 Am-

peres,

Ampere Range Switch S5 In

70-105

Position (Resistive Load)

5 ms 50 V

C. AC Open-Circuit Voltage, Ampere Ranges

Switch S5 In Max Position

5 ms 20 V

D. AC Weld Output, 25 Volts AC, 100 Amperes,

Ampere Range

Switch S5 In 70-105 Position

(Resistive Load)

gndgnd

TM-428 Page 23

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6-5. Idle Control Board/Module PC1 Testing Information

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

Be sure plugs are secure before

testing.

See Section 6-6 for specif

values during testing.

Idle Control Board PC1 (Prior

o Serial No. JH300534)

Idle Module PC1 (Ef

fective

With Serial No. JH300534)

est Equipment Needed:

TM-428 Page 24

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YES

Connect meter (AC) between

terminal G and terminal E.

0 (zero) volts dc

present after 12 to 18 seconds?

Connect meter (DC) between

terminal C (+) and terminal E (–).

0 (zero) volts ac present?

YES

Reinstall cover.

Check for internal

load such as

shorted diode in

Connect a 100 watt light bulb to

100 Hz ac receptacle.

Connect meter (AC) between

terminal G and terminal E.

Minimum of 1 volt ac present?

YES

Disconnect 100 watt light bulb

and meter leads.

Connect meter (DC) between

terminal C (+) and terminal E (–).

+12 volts dc present?

YES

Reinstall cover.

Check connections

to current

transformer CT1.

Engine does not go to power/idle rpm

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

load applied.

main rectifier SR1.

0 (zero) volts dc present?

Connect meter (DC) between

terminal D (+) and E (–).

YES

Connect meter (DC) between

terminal B (+) and terminal E (–).

YES

+12 volts dc present?

Check connections

to Engine Control

switch S2 and

ground connection

(lead 33).

Start

engine. Place Engine Control

switch S2 in Run/Idle position.

Check connections

to Engine Control

switch S2.

Start engine. Place Engine

Control switch in Run/Idle position.

Start engine. Place Engine Control

switch S2 in Run/Idle position; Idle

Lock switch S1 in Unlock position.

Check throttle solenoid TS1

linkage.

Check circuit breaker CB4, throttle

solenoid TS1 connections and

linkage, and control relay CR2.

Replace idle

board/module

PC1

Replace idle

board/module

PC1

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

TM-428 Page 25

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Reinstall cover.

+12 volts dc present?

YES

Engine does not go to weld rpm with

Engine Control switch S2 in Run position.

YES

+12 volts dc present?

Check connections

to Engine Control

switch S2 and

ground connection

(lead 33).

Start

engine. Place Engine

Control switch S2 in Run position.

Check circuit breaker CB4, throttle

solenoid TS1 connections and

linkage, and control relay CR2.

Connect meter (DC) between

terminals D (+) and E (–).

Prior to Serial No. JH300534,

move W

eld/Power switch S1 to

eld position.

Control Relays CR3 and CR4 do not

energize at idle rpm (See Section 5 for

CR3 and CR4 information)

Reinstall cover.

YES

+12 volts dc present?

Connect

meter (DC) between

terminal A (+) and F (–) prior to

Serial No. JH300534, or B (+) and

F (–) ef

fective with Serial No.

JH300534.

Start engine. Place Engine

Control switch in Run position.

YES

0 (zero) volts dc present?

Check control relays

CR3 andCR4.

Place Engine Control switch S2

in Run/Idle position.

Replace idle

board/module

PC1

Replace idle

board/module

PC1

Replace idle

board/module

PC1

Connect meter (DC) between

terminals C (+) and E (–).

TM-428 Page 26

Miller Legend

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

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

Be sure plugs are secure before

testing.

See Section 6-8 for specif

values during testing.

oltage Regulator Board PC2

erminals A Thru G

est Equipment Needed:

6-8. Voltage Regulator Board PC2 Test Point Values Prior To Serial No. KE604176

PC2 Voltage Readings

a) Tolerance – ±10% unless

specified

b) Reference

– to circuit com

mon

(lead 33) unless noted

Receptacle Value

A Circuit

common

18 volts ac input with respect to pin A

Circuit common

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

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

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

TM-428 Page 27

Miller Legend

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

KE604176

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

Be sure plugs are secure before

testing. See Section 6-10 for spe-

cific

values during testing.

oltage Regulator Board PC2

2 Receptacle RC1

est Equipment Needed:

1 2

6-10. Voltage Regulator Board PC2 Test Point Values Effective With Serial No. KE604176

PC2 Voltage Readings

a) Tolerance – ±10% unless

specified

b) Reference

– to circuit com

mon

(lead 33) unless noted

Receptacle Pin Value

RC1 1 18

volts ac input with respect to pin 5

Not used

18 volts ac input with respect to pin 5

Circuit common

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

Not used

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

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

TM-428 Page 28

Miller Legend

6-11. Optional Remote Control Board PC3 Testing Information

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

Be sure plugs are secure before

testing. See Section 6-12 for spe-

cific

values during testing.

Remote Control Board PC3

2 Receptacle RC1

est Equipment Needed:

6-12. Optional Remote Control Board PC3 Test Point Values

PC3 Voltage Readings

a) Tolerance – ±10% unless

specified

b) Reference

– to circuit com

mon

(lead 33) unless noted

Receptacle Pin* Value

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 contac

tor 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 con

tactor control switch open

10 (K)

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 29

Miller Legend

6-13.

Optional Remote Capacitor Board PC5 T

esting Information Effective W

ith Serial No.

KD346698

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

Be sure plugs are secure before

testing. See Section 6-14 for spe-

cific

values during testing.

Capacitor Board PC5

Remote 14 Receptacle RC1

3 Receptacle RC2

erminal K

est Equipment Needed:

6-14. Optional Remote Capacitor Board PC5 Test Point Values Effective With Serial No.

KD346698

PC5 Voltage Readings

a) Tolerance – ±10% unless

specified

b) Reference

– to circuit com

mon

(lead 33) unless noted

Receptacle Pin Value

RC1 A Contact

closure to pin B completes the dc contactor control circuit

+15 volts dc output

Command reference, +4.5 volts dc output

Remote control circuit command

Input command signal from potentiometer wiper

, 0 to +4.5 volts dc input

Chassis ground (lead 33)

RC2 1

Remote control circuit common

Command reference, +4.5 volts dc input

+15 volts dc input

Command signal from potentiometer wiper

, 0 to +4.5 volts dc output

Not used

Contact closure to pin 3 completes contactor control circuit

Terminal K

Chassis ground (lead 33)

TM-428 Page 30

Miller Legend

6-15. Replacing Brushes And Cleaning Slip Rings

A. Checking Brushes And Cleaning Slip Rings

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

Stop

engine and allow to cool.

Brush Holder Retaining Bar

2 Brush Holder Bracket

Remove brush holder bracket.

Keep

hardware for reinstallation.

Brush Holder

Brush With Spring

Brush Holder Cap

Mark and disconnect leads at

caps, and remove brushes from

bracket.

Replace brushes if damaged, or if

brush

at or near minimum length.

6 Slip Rings

Inspect slip rings. Under normal

use,

rings turn dark brown.

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 en

gine.

Install brushes, bracket, and re-

maining generator parts. Adjust

brushes

as shown in Section B.

Reinstall both side panels and top

cover.

Tools

Needed:

1/2 in

5/16 in. (8 mm)

Minimum Length

9/16 in. (14.3 mm)

New Length

Replace

Damaged Brushes

TM-428 Page 31

Miller Legend

B. Adjusting Brush Position

Stop

engine.

After installing brushes, adjust

brush

position as follows:

Brush Holder

2 Brass Sleeve

3 Brush

Slip Ring

Loosen brush holder bracket

mounting

hardware. Move bracket

until brass sleeves are positioned

shown. T

ighten hardware.

Reinstall side panels and cover

operation is still not okay

, have a

qualified machine shop turn and

polish

slip rings.

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

ools Needed:

3/8, 1/2 in

Center

brushes on slip

rings.

Correct Brush Position

op V

iew

Side V

iew

Incorrect Brush Position

1234

3/32 in

(2.4 mm)

Correct

Brush Position

Incorrect

Brush Position

TM-428 Page 32

Miller Legend

6-16. Checking Unit Output After Servicing

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

Check engine speeds, and adjust

if necessary (see Section 8-5).

15 V

AC 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

YStop engine before adjust-

ing

If necessary, adjust slider on R4

until

128 to

132 volts ac is obtained

at RC4. Do not exceed 132 volts

ac.

4DC

eld Output T

erminals

Turn

Fine Amperage control R1 to

max.

With no load applied and en

gine running at weld rpm, there

should

be 70

to 72 volts dc present

dc weld terminals.

5 Resistor R2

YStop engine before adjust-

ing

correct voltage is not present, ad

just slider on R2 until correct volt-

age is obtained at dc weld termi-

nals.

Do not exceed 72 volts dc.

Stop engine. Allow engine to

cool,

and

then complete pre-operational

checks

in table.

Reinstall cover and side panels.

ools Needed:

Pre-Operational Checks

Wipe engine surfaces clean.

Check labels; replace labels that are unreadable or damaged.

Check and correct any fluid leaks.

Clean weld output and battery terminals.

ighten connections.

Clean outside of entire unit.

Check fuel and oil (see Section 2-4).

TM-428 Page 33

Miller Legend

SECTION 7 – DISASSEMBLY AND REASSEMBLY

7-1. Disassembly Of Unit

Use Section 6-1 to determine if

trouble

in rotor

, stator

, engine or

a combination of these compo-

nents.

Remove sheet metal panels from

unit. Disconnect negative (–) bat-

tery cable from battery. Remove

spark plugs. Mark and disconnect

all

stator leads.

YDo not damage rotor or sta-

tor

during this procedure.

Use hoist and lifting strap to re-

move the engine/generator as-

sembly.

ST-800 710-A

ools Needed:

3/8, 7/16, 1/2, 9/16 in

TM-428 Page 34

Miller Legend

7-2. Disassembly Of Generator

ST-115 942-F

YDo

not

damage stator or rotor wind

ings

during this procedure.

Disassembly

With

engine properly supported with blocks,

remove

hardware securing stator to engine.

Remove

generator parts as needed:

Fan Guard

2 O-Ring

3 Endbell

4 Stator Assembly

Engine Adapter

Fan Rotor Adapter

Rotor Fan

8 Rotor

Ball Bearing

Retaining Ring

Integrated Rectifier SR2

12 Brush Holder Bracket

Brush Holder Retaining Bar

Brush Holder Cap

15 Brush

Brush Holder

Reassembly

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

Use cable ties to secure leads in existing

wiring

harnesses

and away from moving or

hot

parts.

Reconnect negative (–) battery cable.

Prior T

o Serial No. KD523655

fective With Serial No. KD523655

15 ft lb (20 N

.m) A

15 ft lb (20 N

.m)

30 ft lb (41 N

.m) B

20 ft lb (27 N

.m)

25 ft lb (34 N

.m) C

25 ft lb (34 N

.m)

15 ft lb (20 N

.m) D

20 ft lb (27 N

.m)

15 ft lb (20 N

.m) E

15 ft lb (20 N

.m)

Torques:

Hardware may differ from that shown.

1314

TM-428 Page 35

Miller Legend

SECTION 8 – MAINTENANCE

8-1. Routine Maintenance

Recycle

engine

fluids.

Stop engine before maintaining.

See also Engine Manual and mainte-

nance

label. Service engine more

often

during

severe conditions.

8 Hours

Wipe

Spills

Check Fluid

Levels.

See Section 2-4

OIL

Full

20 Hours

Check

And

Clean Spark

Arrestor Screen

25 Hours

Clean

And

Check Air

Cleaner

50 Hours

Clean

And

ighten W

eld

Terminals

100 Hours

Change

Oil. See

Section 8-4 And

Maintenance

Label

Change Oil Filter

. See

Section 8-4 And

Maintenance Label

Clean And

Tighten

Battery

Connections

Clean Cooling

System,

See Engine

Manual

200 Hours

Replace

Fuel

Filter

See Section

8-4.

Replace

Unreadable

Labels

Check

Valve

Clearance

500 Hours

Repair Or Replace

Cracked Cables

Check

Spark

Plugs

1000 Hours

Blow Out Or V

acuum Inside.

During Heavy Service,

Clean Monthly

TM-428 Page 36

Miller Legend

8-2. Maintenance Label

ONAN P218 GAS ENGINE

Check

S-176 891

daily.

Optional

Gasoline

°C

+30

+20

+10

-10

-20

-30

°F

Spark

Arrestor Inspection And Service

20 operating hours -

see Owner’

s Manual

Fuel Grade

Regular or Unleaded

. . . . . . . .

Fuel

Filter

MILLER 066 1

13, Onan 149-2206-01,

. . . . . . . . .

Fram

G10E1

12 V

olt 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.

. . . .

Air

Filter Service 100 hours or less – see Owner

’

s Manual

. . .

Air

Filter Element

MILLER 064 617, Onan 140-2522

. . .

Air

Filter W

rapper

MILLER 065 653, Onan 140-1496

. . .

Spark

Plug Gap

0.025 in. (0.6 mm)

. . . .

Spark

Plug

Champion RS17YX Preferred or

. . . . . . . .

RS14YC

Use

only resistor spark plugs and wires.

+40

+100

Recommended Oil

API Service Classification.

. .

SF, SG, SF/CC, SG/CE

Oil & Filter

Change .

. . . . . . . . .

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

. . . . . . .

Valve

Clearance – Cold

In.

0.005 in (0.13 mm)

. .

Ex. 0.013

in (0.33 mm)

See

Engine Manual for complete engine care. Give engine

Specification and Serial Number when ordering parts.

10W

5W-30

Push And

o Drain Oil:

Pull

1/2 in. ID Hose

Turn CCW

TM-428 Page 37

Miller Legend

8-3. Servicing Air Cleaner

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

YDo not run engine without

air cleaner or with dirty ele-

ment.

Stop

engine.

1 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

TM-428 Page 38

Miller Legend

8-4. Changing Engine Oil, Oil Filter, And Fuel Filter

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

Stop

engine and allow to cool.

Oil Drain V

alve

1/2 ID x 12 in Hose

Oil Filter

Change engine oil and filter ac-

cording

to engine owner

’

s manual.

YClose valve and valve cap

before adding oil and run-

ning

engine.

Fill crankcase with new oil to full

mark

on dipstick

(see Section 8-2).

4 Fuel

Filter

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.

ools Needed:

Full

TM-428 Page 39

Miller Legend

After tuning engine, check engine

speeds with a tachometer. See

table for proper no load speeds. If

necessary, adjust speeds as fol-

lows:

Start engine, and place Engine

Control

switch

in Run/Idle position.

Turn Fine Amperage control to

100.

1 Carburetor

2 Throttle

Solenoid

Power/Idle Speed Adjustment

Power/Idle Speed Rod

4 Lock Nut

Adjustment Nut

Loosen

lock nut and rotate adjust

ment nut until engine runs at pow

er/idle speed. T

ighten lock nut.

eld Speed Adjustment

Place

Engine Control

switch in Run

position.

6 Lock

Nut

Loosen nut.

7 Hex Swivel

Turn swivel until engine runs at

weld

speed. T

ighten lock nut.

eld Speed Governor Spring

Power/Idle Speed Governor

Spring

If a spring becomes loose or dis-

connected,

reattach as shown.

8-5. Adjusting Engine Speed

Tools

Needed:

1860 rpm

(Power/Idle)

3000 rpm

(Weld)

3/8 in,

8, 1

1 mm

ST-116 049-C

Rear V

iew

op V

iew

TM-428 Page 40

Miller Legend

8-6. Overload Protection

Stop

engine.

Circuit Breaker CB4 (Internal

– Not Shown)

CB4 protects the unit from over-

load due to an obstructed throttle

solenoid. If CB4 opens, engine

speed drops to power/idle rpm for

about

10 seconds before

automati

cally

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.

Replace open fuse and reinstall

panel

before operating unit.

F1 continues to

open, check inte

grated

rectifier SR2 and rotor

ools Needed:

3/8 in

ST-152 264-A

Stop

engine and allow to cool.

1 Spark Arrestor Screen

Clean and inspect screen. Re-

place

spark arrestor if screen wires

are

broken or missing.

8-7. Inspecting And Cleaning Optional Spark Arrestor

Tools

Needed:

1/4 in

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

TM-428 Page 41

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. T

o order a copy, proceed as follows:

Know unit Model and Serial or Style Number

Use this list to find diagram number

Include your F

AX number or mailing address with your request.

4 FAX T

echnical Publications Department at 414-735-401

1 or call 414-735-4356.

Model Serial Or Style Number Circuit

Diagram Wiring

Diagram Main Reason

For Change

Miller

Legend Without Re

mote Control

JH2421

14 thru JH300533

SC-1

14 477-A

D-1

17 651

♦♦

JH300534 thru JJ420470

C-1

17 626-B

♦♦

D-123 101

♦♦

Changed PC1 and S1, add

ed 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

Miller Legend With Re

mote Control

JH2421

14 thru JH300533

SC-1

15 947-A

JH300534 thru JJ420470

C-1

18 207-A

♦♦

Changed PC1 and S1, add

ed 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

JH2421

14 thru JH300533

SB-1

13 710

Circuit Board PC2

JH2421

14 thru KE604175

B-049 506-C

♦♦

KE604176 and following

SB-160 891

Circuit Board PC3

♦JH2421

14 thru KA840709

B-1

15 891-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

♦Optional

♦♦ Not

included in this manual

TM-428 Page 42

Miller Legend

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 43

Miller Legend

SC-168 053-A

Figure 9-2. Circuit Diagram For Miller Legend Without Remote Control

Effective With Serial No. KE629034 And Following

TM-428 Page 44

Miller Legend

Coat

terminals with dielectric grade, nonconductive,

electric grease (MILLER Part No. 146 557) or equivalent.

Figure 9-3.

iring Diagram For Miller Legend Without Remote Control

Effective With Serial No. KE629034 And Following

TM-428 Page 45

Miller Legend

SD-168 051-B

TM-428 Page 46

Miller Legend

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 47

Miller Legend

SC-168 054-A

Figure 9-5. Circuit Diagram For Miller Legend With Remote Control

Effective With Serial No. KE629034 And Following

TM-428 Page 48

Miller Legend

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 49

Miller Legend

SB-136 249

POSITIVE

SUPPLY+

OUTPUT

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

TM-428 Page 50

Miller Legend

SB-156 027

Figure 9-10. Circuit Diagram For Optional Capacitor Board PC5

Effective With Serial No. KD346698 And Following

February 1996 Form: TM-428

Effective With Serial No. JH242114

SECTION 10 – PARTS LIST

TM-428 Page 51

Miller Legend

Miller Legend

(Formerly The Legend AEAD-200LE)

CC AC/DC Welding Generator For SMAW, GMAW, GTAW Welding

TM-428 Page 52

Miller Legend

Figure 10-5

Figure 10-1. Main Assembly

20 21

22 23 24 25 26

10 11 27

43 45 46 47

12 13

14 15 16 17 18

Figure 10-2

Figure 10-3

Figure 10-6

TM-428 Page 53

Miller Legend

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

Figure 10-1. Main Assembly

1 ++042 132 REMOTE CONTROL, (Figure 10-6) (Prior to JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ++042 383 REMOTE CONTROL, (Figure 10-6) (Eff w/JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Figure 10-5 CONTROL

ANEL, w/components 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 113 302 UPRIGHT, base (Prior to KA780148) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 129 384 UPRIGHT, base (Eff w/KA780148 thru KA892304) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 136 057 UPRIGHT, base (Eff w/KA892305 and on) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 107 342

SEAL, lift eye

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 113 303 P

ANEL, side

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +113 304 COVER, top (Prior to JJ365634) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +114 557 COVER, top (Eff w/JJ365634 thru KF812088) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +173 209 COVER, top (Eff w/KF812089) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 304 BLANK, snap-in nyl .250mtg hole (Eff w/JJ365634 thru KB133271) 2.

. . . . . . . . . . . . . . . . . . .

. . . . . . . .

143 397 BLANK, snap-in nyl .312mtg hole (Eff w/KB133272 thru KF812088) 2.

. . . . . . . . . . . . . . . . . . .

. . . . . . .

7 108 487 LABEL, warning falling equipment etc 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 113 439 PANEL, rear lower (Prior to KA780148) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 128 789 PANEL, rear lower (Eff w/KA780148 thru KA892304) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 136 059 PANEL, rear lower (Eff w/KA892305 and on) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 095 970 STRIP, nprn wsl eng firewall 18 in 2.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 088 731 BUSHING, snap-in nyl .375 ID 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 PLG5 HOUSING, (part of engine wiring harness).

. .

. . . . . . . . . . . . . . . . . . .

113 248 TANK, fuel (Prior to KA780148) (consisting of) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

015 603 CAP, tank fuel 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 345 NECK, tank fuel 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 685 TUBE, pick up fuel 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 863 CLAMP, hose 2 1/16-3 clamp dia (Prior to KA780148) 2.

. . . . . . . . . . . . . . . . . . .

107 346 HOSE, fuel tank (Prior to KA780148) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107 324 BRACKET, support pipe filler (Prior to KA780148) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

107 343 GROMMET, rubber neck filler fuel (Prior to KA780148) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

113 486 COVER, fuel tank (Prior to KA780148) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 392 HOLD DOWN, fuel tank (Prior to KA780148) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

113 294 SUPPORT, center mtg engine (Prior to KA780148) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

12 147 601 CAP, tank screw-on w/vent 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 130 123 TANK, fuel 7.5gal (Eff w/KA780148 thru KG037343) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 177 606 TANK, fuel 7.5gal (Eff w/KG037344 and on) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 145 976 HOSE, nprn SAE .250 ID 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 084 173 CLAMP, hose .460–.545clp dia 2.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 066 113 FILTER, fuel inline .250 (included w/engine) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CLAMP, hose .460–.545clp dia (included w/engine) 2.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 HOSE, nprn SAE .250 ID (included w/engine) (order by ft) 1ft.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 135 627 ENGINE, gas elect start (Prior to KG037344) (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 178 479 ENGINE, gas elect start (Eff w/KG037344) (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 251 FITTING, pipe brs cap .375NPT (Prior to KF933389) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

113 250 FITTING, pipe galv nipple L .375NPT (Prior to KF933389) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

20 165 271 VALVE, oil drain (Eff w/KF933389) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 107 297 MUFFLER, exhaust engine (Prior to KF926822) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 164 353 MUFFLER, exhaust (Eff w/KF926822) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 106 977

SOLENOID, 12VDC 20A

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 113 563 BRACKET, mtg solenoid (Prior to JK595850) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 128 534 BRACKET, mtg solenoid(Eff w/JK595850) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 128 869

LINKAGE KIT

, (Prior to JJ404117) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 128 431 SWIVEL, in-line .250-28 (Eff w/JJ404117) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 128 533 LINK, throttle (Eff w/JJ404117) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 064 646 SPRING, high speed 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137 046 TUNE-UP & FILTER KIT, (consisting of) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

064 617 ELEMENT, air cleaner 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

065 251 OIL FILTER 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121 652 FILTER/CLAMPS, fuel 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

065 709 SP

ARK PLUG

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-428 Page 54

Miller Legend

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

Figure 10-1. Main Assembly (Continued)

27 107 308 HOLD DOWN, bat (Prior to KB113874) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 146 697 HOLD DOWN, bat (Ef

f w/KB1

13874 thru KF959176) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 165 631 HOLD DOWN, bat (Eff w/KF959177 and on) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 493 BUSHING, snap-in nyl .625 ID x .875mtg hole (Prior to KA780148) 2.

. . . . . . . . . . . . . . . . . . .

. . . . . . . .

28 165 630 BOLT, J stl .250–20 x 6.125 (Eff w/KF959177) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 168 385 LABEL, warning battery explosion 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 511 BRACKET, support cover (Prior to KF812089) 2.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

30 107 270 DOOR, access battery (Prior to KF959177) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 175 887 DOOR, access battery (Eff w/KF959177) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 088 577 CABLE, bat pos (Prior to KF959177) (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 167 731 CABLE, bat pos (Eff w/KF959177) (included w/engine) (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . .

071 970 COVER, cable bat post red 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 BAT 071 678 BATTERY, stor 12V (Prior to KF959177) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 BAT 168 037 BATTERY, stor 12V (Eff w/KF959177) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 923 BOOT, insulator term post red (Prior to KA780148) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

135 571 BOOT, insulator term post red ( Eff w/KA780148 thru KC220663) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . .

108 081 TERMINAL PROTECTOR, battery post mtg 2.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

020 279 CLAMP, stl cushion .750 dia x .281mtg hole (Eff w/KA780148) 2.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .

33 107 753 CABLE, bat neg (Prior to KA780148) (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 023 641 CABLE, bat neg (Eff w/KA780148 thru KE668694) (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . .

33 167 730 CABLE, bat neg (Eff w/KE668695) (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

071 971 COVER, cable bat post blk 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 Figure 10-2 GENERATOR 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 113 298 BASE, (Prior to KA780148) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 132 195

BASE, (Ef

f w/KA780148 thru KB113873) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 146 710

BASE, (Ef

f w/KB1

13874 and on) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 134 792 LABEL, warning general precautionary engine etc 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 057 360 BLANK, snap-in nyl 1.375mtg hole 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 DC-Z 113 450 STABILIZER 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 AC-Z 113 451 REACTOR 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 SR1 142 503 RECTIFIER, si 1ph 300A 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 113 562 BRACKET, mtg resistor (Prior to JK559100) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 126 072 BRACKET, mtg-resistor (Eff w/JK559100) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 114 544 PANEL, front lower 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 Figure 10-3 PANEL, front w/components 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 CT1 105 370 TRANSFORMER, current 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 012 571 HOLDER, fuse mintr 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 *083 596 FUSE, mintr cer 12A 250V 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 R2,4 008 951 RESISTOR, WW adj 180W 12 ohm 2.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 R3,VR1 046 819 SUPPRESSOR 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 RC5 116 045 HOUSING PLUG & PINS, (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 633 CONNECTOR, rect univ 084 pin 20-14ga 6.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 109 994 LABEL, warning engine fuel can cause fire 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 013 367 LABEL, warning moving parts can cause serious injury 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 475 KIT, label (Prior to KF959177) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176 908 KIT, label (Eff w/KF959177) 1.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

*Recommended Spare Parts.

++Optional Parts

BE SURE T

O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P

ARTS.

TM-428 Page 55

Miller Legend

Figure 10-2. Generator (Figure 10-1 Item 34)

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

1 013 367 LABEL, warning fan 2.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 115 500 LABEL, engine maintenance Onan (Prior to KA780148) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 134 092 LABEL, engine maintenance Onan P218 (Eff w/KA780148 thru KF959176) 1.

. .

. . . . . . . . . . . . . .

2 176 891 LABEL, engine maintenance Onan P218 (Eff w/KF959177 and on) 1.

. .

. . . . . . . . . . . . . . . . . . . . . .

3 +113 410 GUARD, fan gen 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 153 297 ENDBELL, gen (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 143 220 O-RING, 2.859 ID x .139CS 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 165 756 STATOR, gen 60Hz (Prior to KD438829) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 162 138 STATOR, gen 60Hz (Eff w/KD438829) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 165 755 STATOR, gen 50Hz (Prior to KD438829) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 162 141 STATOR, gen 50Hz (Eff w/KD438829) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 017 702

ADAPTER, engine

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

003 455 KEY, woodruff .250 x .750 SAE No. 91 (part of engine) (Prior to KA780148) 1.

. . . . . . . . . . . . . . . .

. . .

8 021 934 ADAPTER, fan rotor (Prior to KA780148) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 134 981 ADAPTER, fan rotor (Eff w/KA780148) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 008 917 WASHER, flat stl .343 ID x 2 (part of engine) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 049 286 ROT

OR ASSEMBL

Y, gen (consisting of) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 017 624 FAN, rotor gen 1.

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12 053 390 BEARING, ball rdl sgl row 1.37 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 024 617 RING, retaining ext 1.272 shaft 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 348 KEY, stl .250 x .250 x .750 1.

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 SR2 035 704 RECTIFIER, integ 40A 800V 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 007 250 BRACKET, mtg brushholder 1.

. .

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16 047 878 BAR, retaining brushholder 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 161 306 CAP, brushholder 3.

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18 *126 984

BRUSH w/SPRING

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 005 614 HOLDER, brush 3.

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ST-115 942-F

12 3

Figure 10-2. Generator

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

*Recommended Spare Parts.

BE SURE T

O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P

ARTS.

TM-428 Page 56

Miller Legend

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

Figure 10-3. Panel, Front w/Components (Figure 10-1 Item 43)

1 RC1,2 604 176 RECEPTACLE, str dx grd 2P3W 15A 125V (Prior to KE629034) 2.

. .

. . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V P&S 5266 DF.

. . . . . . . . . . . . . . . . . . .

. . .

1 RC1,2 167 657 RECEPTACLE, str dx grd 2P3W 15A 125V (Eff w/KE629034) 2.

. .

. . . . . . . . . . . . . . . . . .

2 CB1,2 115 427 CIRCUIT BREAKER, man reset 1P 25A 250VAC (Prior to KE629034) 2.

. .

. . . . . . . . . . . .

2 CB5,7 168 057 CIRCUIT BREAKER, man reset 1P 20A 250V

AC (Ef

f w/KE629034) 2.

. .

. . . . . . . . . . . . . .

3 113 315 PANEL, front (Prior to JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 130 352 PANEL, front (Eff w/JK713332 thru KB133271) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 143 383 PANEL, front (Eff w/KB133272 thru KF790319) 1.

. .

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3 170 554 PANEL, front (Eff w/KF790320 and on) 1.

. .

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4 S5 005 563 SWITCH, selector (Figure 10-4) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R1 081 712 RHEOSTAT, WW 100W 30 ohm 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S4 ++011 609 SWITCH, tgl SPDT 15A 125VAC (Prior to JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S4 ++011 611 SWITCH, tgl DPDT 15A 125V (Eff w/JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 RC7 035 523 CONNECTOR, circ MS/MET 5skt sz 16S rect MS-3102A-16S-8S.

. .

. . . . . . . . . . .

Amphenol (Prior to JK713332) 1.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 6 7

910

14 15

28 29

ST-115 943-J

Figure 10-4

Figure 10-3. Panel, Front w/Components

TM-428 Page 57

Miller Legend

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

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.

. .

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9 S2 172 070 SWITCH, ignition 1.

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10 CB3 083 432 CIRCUIT BREAKER, man reset 1P 10A 250V 1.

. .

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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.

. .

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14 ♦042 130 METER KIT, (Prior to KD548030) (consisting of) 1.

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HM 032 936 METER, hour 1.

. . . . . . . . . .

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14 145 247 METER, hour 12-24VDC (Eff w/KD548030) 1.

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15 CB1,2 144 474 CIRCUIT BREAKER, man reset 1P 25A 250V

AC (Ef

f 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.

. .

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22 601 976 SCREW, cap stl hex hd .500-13 x 1.500 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 039 049 TERMINAL BOARD, red 1.

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23 039 045 TERMINAL BOARD, black 1.

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23 039 040 TERMINAL BOARD, neutral 1.

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24 601 880 NUT, stl hex jam .500-13 1.

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25 039 044 BUS BAR, term bd 1.

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26 601 879 NUT, stl hex full fnsh .500-13 1.

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27 073 756 STAND-OFF, No. 6-32 x .625 lg x .250 hex (Eff w/KD344394) 2.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

153 501

HOUSING PLUG & SOCKETS, (Ef

f 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.

. .

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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

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

. .

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34 ++021 385 BOOT, tgl switch lever 1.

. .

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35 115 493 HANDLE, switch range 1.

. .

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++Part of Remote Control Option

♦Effective w/KD548030 Optional Meter Kit became Standard Equipment.

BE SURE T

O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P

ARTS.

TM-428 Page 58

Miller Legend

Description Quantity

Part

No.

Item

No.

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

005 563

1 005 562 BRACKET, mtg-switch 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 005 561 SHAFT, rotor 1.

. .

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3 005 564 INSULATOR, screw switch 1.

. .

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4 605 276 SCREW, cap stl hex hd .250-20 x 1.250 1.

. .

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5 005 559 CONTACT BOARD, movable switch 1.

. .

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6 005 560 CONTACT, switch movable 1.

. .

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7 008 485 SPACER, contact switch 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 005 566 CONTACT BOARD, stationary switch 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 011 644 CONTACT, stationary switch 7.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 052 405 SPRING, pressure contact switch 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 052 404 CONTACT, movable switch 1.

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12 005 557 BUS BAR, switch range 1.

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13 005 558 SPRING, selector switch 1.

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ST-097 264-A

Figure 10-4. Switch, Selector

BE SURE T

O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P

ARTS.

TM-428 Page 59

Miller Legend

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

Figure 10-5. Control Panel, w/Components (Figure 10-1 Item 2)

1 1T 038 601 BLOCK, term 30A 9P (Prior to JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1T 130 648 BLOCK, term 30A 10P (Eff w/JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 113 682 BRACKET, mtg components (Prior to JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 130 649 BRACKET, mtg components (Eff w/JK713332) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 083 147 GROMMET, scr No.8/10 4.

. .

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4 PC2 049 404 CIRCUIT CARD, regulator 115V (Prior to KE604176) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC2 160 888 CIRCUIT CARD, voltage regulator (Eff w/KE604176) (Figure 10-7) 1.

. .

. . . . . . . . . . . . . . . .

PLG1 168 071 CONNECT

OR & SOCKETS, (Ef

f w/KE604176) (consisting of) 1.

. . . . . . . . .

. . . . . . . . . . . . . . . .

114 066 CONNECTOR, rect skt 20-14ga 9.

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 CR4 113 247 RELAY, encl 12VDC DPDT 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 CR3 044 588 RELAY, encl 12VDC 3PDT 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CR2 173 069 RELAY, encl 12VDC SPDT 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB4 045 061 CIRCUIT BREAKER, auto reset 24VDC 7A 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC1 113 492 CIRCUIT CARD, weld/idle (Prior to JH300534) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC1 142 725 MODULE, pull to weld/power delay (Eff w/JH300534) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 D4 059 389 DIODE, rect 3A 1000V SP (Prior to JH300534) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 D4,5 059 389 DIODE, rect 3A 1000V SP (Eff w/JH300534) 2.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 T1 116 083 TRANSFORMER, control (Prior to KE604176) 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 T1 167 404 TRANSFORMER, control (Eff w/KE604176) 1.

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12 038 620 LINK, jumper term blk 30A 1.

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D6 117 566 DIODE, rect 6A 600V 1.

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ST-114 309-B

Figure 10-7

Figure 10-5. Control Panel, w/Components

BE SURE T

O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P

ARTS.

TM-428 Page 60

Miller Legend

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

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

+042 383

+042 132

1 PC3 136 246

CIRCUIT CARD ASSEMBL

Y, remote control 1.

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 110 375 STAND-OFF SUPPORT, PC card 4.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 116 086 BRACKET, mtg remote control (Prior to JK563388) 1.

. .

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3 125 873 BRACKET, mtg remote control (Eff w/JK563388) 1.

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4 CR5 052 603 RELAY, encl 110VDC DPDT 1.

. .

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5 007 532 CLAMP, capacitor 1.000dia 1.

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6 C5 059 887 CAPACITOR, polyp met film 10uf 220V 1.

. .

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7 2T 116 005 BLOCK, term 10A 7P 1.

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8 108 023 LINK, jumper term blk 10A 4.

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9 PLG6 115 091 HOUSING PLUG & SOCKETS, (consisting of) 1.

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113 746 TERMINAL, female 1skt 18-24W 10.

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SB-116 028

Figure 10-6. Remote Control, Option

+See Figure 10-3 for additional parts not listed

BE SURE T

O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P

ARTS.

TM-428 Page 61

Miller Legend

Description Quantity

Part

No.

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

Dia.

Mkgs.

PC2 160 888

A50 165 411 IC, linear 2904 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C1 003 530 CAPACITOR, cer mono 1uf 50VDC 1.

. . . . . .

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C50 119 199 CAPACITOR, polye met film 1uf 50V 1.

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C51 053 992 CAPACITOR, cer disc .001uf 1000VDC 1.

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C52 000 348 CAPACITOR, tantlm .47uf 35V 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C53 005 023 CAPACITOR, tantlm 2.2uf 20V 1.

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C54 072 935 CAPACITOR, elctlt 33uf 35VDC 1.

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C55 137 463 CAPACITOR, polye met film .22uf 100VDC 1.

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C56 072 113 CAPACITOR, tantlm 4.7uf 35VDC 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C57 028 292 CAPACITOR, cer disc .005uf 1000VDC 1.

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D50 028 351 DIODE, sig 200mA 75V SP 1.

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D51 049 641 DIODE, zener 27V 1W 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D52-54 026 202 DIODE, rect 1A 400V SP 3.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D55-58 070 250 DIODE, rect 3A 600V 4.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D59 030 529 DIODE, rect 22A 600V RP 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Q50 039 355 TRANSISTOR, ujt 15mA 40V 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Q51,52 037 200 TRANSISTOR, NPN 200mA 40V 2.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Q53,54 049 642 THYRIST

OR, SCR 8A 600V

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R50 094 447 RESISTOR, MF .25W 681K ohm 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R51 044 789 RESISTOR, MF .25W 100K ohm 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R52 035 829 RESISTOR, MF .25W 1.5K ohm 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R53,54,65 072 559 RESISTOR, MF .25W 22.1K ohm 3.

. .

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R55 115 530 RESISTOR, MF .25W 2.67K ohm 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R56,64 000 885 RESISTOR, MF .25W 10K ohm 2.

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R57,62 028 285 RESISTOR, C .5W 100 ohm 2.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R58,63 035 823 RESISTOR, MF .25W 100 ohm 2.

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R59 072 559 RESISTOR, MF .25W 22.1K ohm 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R60 074 026 RESISTOR, C .25W 150 ohm 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R61 138 301 POTENTIOMETER, cermet trmr 1/T .5W 25K ohm 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R66 093 030 RESISTOR, MF .25W 15K ohm 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R67 093 032 RESISTOR, MF .25W 26.7K ohm 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R68 108 437 RESISTOR, MF .25W 4.75K ohm 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R69 049 439 RESISTOR, C 2W 47K ohm 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R70 074 099 RESISTOR, C 1W 150 ohm 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R71 030 707 RESISTOR, C 1W 47 ohm 1.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC1 160 892 CONNECTOR, rect 9 pin 3 row rcpt 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VR50 083 772 IC, rgltr 7815 1.

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SA-160 889

Figure 10-7. Circuit Card, Voltage Regulator PC2

BE SURE T

O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P

ARTS.

Notes

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