Miller Electric AEAD-200-LE User's Manual
Contents
1. for PC1 data d Stop engine before checking resistance R1 29 ohms R2 34 ohms See Section 6 13 35 ohms for PC5 data R4 2 ohms R5 2 ohms R6 thru R17 Less than 1 ohm 1 RC2 4 gt RC1 D 5 2 1 2 2 gt PETB ciere DE See Section RCI A RC2 PLG2 RC2 5 gt 6 11 5 33 REC gt n RMT O SA 59 60 22 63 or PC3 data PANEL 7 79 37 4 RCI PLGS REMOTE CONTROL B t D E F 6 H J K lt I PDA gt o 349 37 54 m 49 48 37 xp PLG6 33 25 i B D E F G gt 24 21 21 21 25 26 33 35 27 ms 24 Field flashing z V14 R17 Ei L disconnect relay CR5 2 E Se gt 1 See Section Au 25 NONE rn s OS 6 16 for R2 and SPRINGS BACK TO LALAN 1 12 R4 adjustment EST 32 7 12 15 EXCITER REV FIELD 548 1 X X EX EX 2 RMT PANEL R1 R2 3 x CB3 4 x 5 x V16 V17 i cu TRE RE A RIS 45 27 37 VE 43 v 2 Vas gt ast V11 V12 8222 DL PRESSURE 9 oL V13 R12 SWITCH NO 52 Qo Throttl rottle control relay Ir L em CR2 energized IGNITION at weld rpm So 2 223 CONTROL IDLE BOARD 2 OPTIONAL EE ALTERNATOR ZA 35 2 VOLT Ts 651 amp Field current EXT 34 control relay CR3 m m m 982. February 1996 Form Effective With Serial No JH242114 TM 428 TECHNICAL MANUAL Service And Parts Miller Legend Formerly The Legend AEAD 200LE CC AC DC Welding Generator For SMAW GMAW GTAW Welding Weld Rated Maximum in rip Output Welding Open Circu qure Fuel Capacity Engine Range Output it Voltage 9 225 A 25 V Single Phase CC AC 35 225A 10096 Duty 80 5 kVA KW 42 21 Cycle 120 240 V AC 60 Hz Onan P218 Air Cooled And 7 5 281 Tank Two Oylinder Four Cycle 200 A 25 V Single Phase Gasoline Engine CC DC 25 200 100 Duty 72 1 15 100 2 cover tm 4 95 ST 140 091 1996 MILLER Electric Mfg Co PRINTED IN USA TABLE OF CONTENTS Miller Customer Service Department at 414 735 4505 800 637 2348 in USA or 414 735 4136 outside USA SECTION 1 SAFETY PRECAUTIONS FOR SERVICING 1 1412 eSymboltUsage xi e b e Led ee e POR 1 1 2 Servicdng Hazards GENE E E Rd 1 1 3 EMF Information peter ed Fee eter o tuo aunt sd tes 2 SECTION 2 INSTALLATION boe biu eee es 3 2 1 Installing Welding Generator 3 2 2 Dimensions Weights And Operating Angle
3. ah ent FRI PNE 1 EIL MEM 113 298 BASE Prior to 780148 1 du s DD oda awed tla ten 132 195 BASE w KA780148 thru 113873 1 eSB ud etat and 146 710 w KB113874 on 1 Mares 134 792 LABEL warning general precautionary engine etc 1 ESO te Meals 057 360 BLANK snap in 1 375mtg hole 1 ses 225119450540 STABILIZER 2 esca ae Su Ragone daa Rn doped nn dos 1 39 2 113 451 REACTOR 1 40 5 1 142503 RECTIFIER si 1ph 300A _ 1 E 113 562 BRACKET mtg resistor Prior to JK559100 1 D pe 126 072 BRACKET mtg resistor 559100 1 Soda ets 114544 PANEL front lower 1 ABs scies ario Figure 10 3 PANEL front w components 1 44 105 370 TRANSFORMER 1 wie eka hen 012571 HOLDER fuse mintr 1 083 596 FUSE mintr cer 12A 250V 1 47
4. Control R1 3 Voltage 60 Hz Auxiliary 1 2 Regulator Power BEE Revolving N V Stator Windings Engine gt Fields Rotor 2 100 Hz Exciter Auxiliary Weld Power 5 8 4 Throttle Integrated F Solenoid Rectifier 582 1 ET TS1 6 9 Control Current Relay Transformer www CR5 10 Idle Module PC1 Idle Lock Switch S1 Control Relays CR2 CR3 CR4 Breaker CB3 100 Hz Auxiliary Power Receptacle RC4 TM 428 Page 12 Miller Legend 11 CR4 gt Transformer 14 15 30160 De Breakers uxiliary Power CB1 CB2 Receptacles CB5 CB7 RC1 RC2 RC3 19 Ampere m Ranges Switch S5 20 25 Electrode And Work AC Weld Output Terminals 21 HF Filter Main Board Rectifier PC4 SR1 Stabilizer DC Z 24 Negative DC Weld Output Terminals 13 Remote Control Switch S4 Selects Panel or remote amperage control 14 Circuit Breakers CB1 CB2 CB5 And CB7 Protect 50 60 Hz auxiliary power receptacles RC1 RC2 and RC3 from overload 15 50 60 Hz Auxiliary Power Re ceptacles RC1 RC2 And RC3 Provide connection points and power for auxiliary equipment 16 Circuit Breaker CB3 Protects 100 Hz auxiliary power re ceptacle RC4 from overl
5. For 60 Hz For 60 Hz Auxiliary Power Auxiliary While Welding Power Only 290 Lock UNLOCK RUN IDLE RUN IDLE MU MU E N N 0 100 100 PANEL PANEL 7 8 6 0 0 8 8 Ref ST 168 046 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 9 Total Auxiliary Power Output Combined output of receptacles limited to the 5 KVA 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 Miller Legend TM 428 Page 11 SECTION 5 THEORY OF OPERATION 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 3 Stator Windings Supply power to exciter auxiliary power and weld circuits 4 Fuse F1 Protects exciter excitation winding from overload 5 Integrated Rectifier SR2 Changes ac output of stator wind ings to dc to supply excitation current to the exciter revolving field 6 Control Relay CR
6. A 59 lt 9 23 919 294 0 2 35 epa lt E Z 8 124 i Gel SUNMO oy 54 3 ze 3 128 ALM lt 11249 Effective With Serial No KE629034 And Following TM 428 Page 47 Figure 9 5 Circuit Diagram For Miller Legend With Remote Control Miller Legend OUTPUT 2 12 0 COMMON OUTPUT SB 113 710 Figure 9 6 Circuit Diagram For Idle Control Board PC1 Effective With Serial No JH242114 Thru JH300533 15U 15U 1 UIN VOU RCI 876 uns 052 053 n o 5 RCI 5 RE Ret 054 lt RC1 C54 R54 RC1 RC1 POWER AND GROUND 850 8 1SU 4 GND GND 055 N Ret SB 160 891 Figure 9 7 Circuit Diagram For Voltage Regulator Board PC2 Effective With Serial No KE604176 And Following TM 428 Page 48 Miller Legend OUTPUT lt POSITIVE 3 SUPPLY INPUT 02 OUTPUT 8 CH OUTPUT CONTROL CONTROL CH OUTPUT 18 WIPER OUTPUT CONTROL CONTROL WIPE NEGATIVE i SUPPLY IN SUPPLY COMMON OUTPUT CONTROL CCH CCH OUTPUT CONTROL 1 06 RI 3 REMOTE 9 con CONTACTOR NACI REMOTE CONTACTOR 29 REMOTE 4 ACTIVATE Anti r 8 m REMOTE CTIURTE z c 5 ia ACTIVATE CRET POWER GROUND NETS FOR CHIPS oci 6 150 SB 136 249 Figure 9 8 Circuit Diagram For Option
7. 248 R2 24A CR3 8 2 2 amp STATOR 7 7 2 eh cT a J A3A PCI G 5 cx 13A AC Z RS CB5 33S GND 2 S3A STATOR SIA STATOR S4ACCTI 5 52B IT E 92A STATOR 7 5 OPTION El c t NE 50 crci 2 8 09 60 1 1 8 09 lt a 4 na i z z c Zu F 33U STATOR _65 7 _64 5 33H GND GND STUD GND 2 POS DC WELD o AC NEG 7 WORK SA DC Z 5 1 lt m T 5 26 882 000000 5 5 tL g 330 S RING a 2 E 4 5 R4 CM1 2 3 4 lt 5 EA
8. 3IARRES S VOLTAGE By 87 11 REGULATOR Qo o I Em 87A AC B cB4 186 Ws 5 3 5 3482 3889 45 lt Q 9 55544 85 554553 alg 9 on 2 lt lt lt lt lt mim D8 oE 5 1 4 do Ou 5 E a b SPARK SPARK lt lt PLUG LUG 5 5 8 Xu 2 2 mu iD 8 x as ee wl HB lt AS 5 SOLENOD 5 589 44354854 7 56 6 4 S87 PLG1 4 PLG5 RC5 seen PRESSURE SWITCH 45 1 4 n GO 40 2 85 45 52 3 12V STARTER PC2 p ee BATTERY 90 QO IGNITION CONTROL DS 3152 4 7 8 ri o 2 PE AWS L 1 unus PN GND 33U GND lt 4 8 lt a lt 2 419 8 ol S S amp 810 Di 5 84 ala 007 WELD EXCITER 06 2 STATOR STATOR KA ke SA AC WORK 55 Coat terminals with dielectric grade nonconductive electric grease MILLER Part No 146 557 or equivalent Figure 9 3 Wiring Diagram For Miller Legend Without Remote Control Effective With Serial No KE629034 And Following TM 428 Page 44 Miller Legend HM 33P GND 35B CR2 30 5 5 1 37D 1T k 32A CR3 8
9. Optional Not included in this manual Miller Legend TM 428 Page 41 5 Q 9 o f 181 aalav s 101409 NOILINSI gt 1 u 6 amp 313 gt 0 8 34055344 710 euo 2s WNIWYSL 8 OL 035070 X SNIGNIM U3MOd 28 30191934 2 NOILISOd 3101 01 XOv8 SONINdS 39V1 DA m QD SNIONIM ONTONIM va zou 4 d 6r 00820246 e o o o ou f H 2 TE 72 9 4 128 20 x 9 X M SC 114 477 A Miller Legend Effective With Serial No JH242114 Thru JH300533 Figure 9 1 Circuit Diagram For Miller Legend Without Remote Control TM 428 Page 42 SC 168 053 A N NE er 2 85 1 ii ca ler l 1088 N 49
10. RING retaining ext 1 272 shaft 1 en Boa 602 348 KEY 51 250 x 250 x 750 1 14 SR2 035 704 RECTIFIER integ 40A 800V 1 god tds 007 250 BRACKET mtg brushholder 1 s a 047 878 BAR retaining 0 1 zs dfe ductos 161306 CAP brushholder 3 126 984 BRUSH w SPRING 3 TS o cnius 005 614 5 HOLDER shai BET 3 ST 115 942 F Figure 10 2 Generator When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Miller Legend TM 428 Page 55 Item Dia Par A Mkgs No Description Quantity Figure 10 3 Panel Front w Components Figure 10 1 Item 43 1 1 2 604 176 RECEPTACLE str dx 2P3W 15 125V Prior to KE629034 2 073690 PLUG str grd armd 2P3W 15 125V P amp S 5266 DF 1 1 2 167657 RECEPTACLE str dx 2P3W 15 125V Eff w KE629034 2 2 CB1 2 115 427 CIRCUIT BREAKER man reset
11. v gt Z ao 5 g TE 1 2 m US ANNO SNG M V V S3MOd Xv 76 00007 2 MM OL 03501 X 2 20 z Oo ENNM 89 x 5 MD1V 1938 SNINA T E NON Wd xx z 22 00002 m d x Y V LH lest lt x 92 solve 0134 SNATOAZY 1315 lt pz lt lt 5 2 1 4 NOWLISOd ajr CES 771000 09000010 DEVE SENS 1 SNCNM CX a ONCNIM 16 cuu p aad Xv 49 S lec 2 ae NEF e i es 45 START gt eo if 12 ez Z Z IZ 7 B 0 0 0 0 0o o o XE 92 9 4 13 0 2 8 Eier x O f LZ 29 25 je 589 sZ SNOLLONALSN Sul 5 88 06 Q BE 9 X M Yad G315 NNOJ A ER uu O 1 z lt lt TE lt 9 y 0 H 9 4 3 0 2 8 DHINOO 440 30V1d323 1239 Se T TE 6 z m tU A m ze o lt N GG WSO 5 15 9 29 12 08 55 ne 5 ge
12. uH 130 649 BRACKET mtg components Eff 713332 WOMIT 083 147 GROMMET scr No 8 10 24 2 049 404 CIRCUIT CARD regulator 115V Prior to KE604176 4 PC2 160 888 CIRCUIT CARD voltage regulator Eff w KE604176 Figure 10 7 PLG1 168 071 CONNECTOR amp SOCKETS Eff w KE604176 consisting of qapa 6 g a bq 114066 CONNECTOR rect skt20 14ga 5 CR4 113 247 RELAY 12VDC 6 044 588 RELAY 12VDC ee 7 CR2 173 069 RELAY 12VDC 8 CB4 045 061 CIRCUIT BREAKER auto reset 24VDC 7A 9 PC1 113 492 CIRCUIT CARD weld idle Prior JH300534 9 PC1 142 725 MODULE pull to weld power delay Eff w JH300534 10 04 059 389 DIODE rect 1000V SP Prior to JH300534 10 04 5 059 389 DIODE rect 1000V SP Eff w JH300534 zo ens 116 083 TRANSFORMER control Prior to KE604176 langes T1 167 404 TRANSFORMER control Eff w KE604176 038 620 LINK
13. 15 6 1 Troubleshooting Tables HH 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 83 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 Testing Information 28 6 12 Optional Remote Control Board Test Point Values 28 6 13 Optional Remote Capacitor Board PC5 Testing Information Effective With Serial No KD346698 ee oheew doi vs 29 6 14 Optional Remote Capacitor Board PC5 Test Point Values Effective With Serial No KD346698 x oc fed eas sans Pend esie bonis ebbe Medius 29 6 15 Replacing Brushes And Cleaning Slip Rings 30 6 16 Chec
14. R2 4 008 951 RESISTOR WW adj 180W 12 ohm 2 48 R3 VR1 046 819 55 1 49 RC5 116045 HOUSING PLUG amp PINS consisting of 1 t enne 113 633 CONNECTOR rect univ 084 pin 20 14ga 6 EUER 109 994 LABEL warning engine fuel can cause fire 1 dert eet 013367 LABEL warning moving parts can cause serious injury 1 Ain Ced yd ated 135 475 KIT label Prior to KF959177 E MEE 176 908 KIT label 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 TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS TM 428 Page 54 Miller Legend Item Dia Part T Mkgs Description Quantity Figure 10 2 Generator Figure 10 1 Item 34 e US a ER etes 013 367 LABEL warning fan 2 EM ECT 115 500 LABEL engine maintenance Onan Prior to KA780148 1 134 092 LABEL engine maintenance Onan P218 w KA780148 thru KF959176 1 176 891 LABEL engine maintenance On
15. YES Connect meter DC between Check throttle solenoid TS1 terminal C and terminal E linkage Replace idle 12 volts dc present gt board module PC1 Reinstall cover YES Check circuit breaker CB4 throttle solenoid TS1 connections and linkage and control relay CR2 Disconnect 100 watt light bulb and meter leads Reinstall cover TM 428 Page 24 Miller Legend Engine does not go to weld rpm with Engine Control switch S2 in Run position Connect meter DC between terminals D and E Start engine Place Engine Control switch S2 in Run position Prior to Serial No JH300534 move Weld Power switch S1 to Weld position Control Relays CR3 and CR4 do not energize at idle rpm See Section 5 for and information Connect meter DC between terminal A and F prior to Serial No JH300534 or B and F effective with Serial No JH300534 Start engine Place Engine Control switch in Run position Check connections NO Replace idle 0 zero volts dc present gt board module PC1 YES Place Engine Control switch S2 in Run ldle position NO Replace idle 12 volts dc present gt board module PC1 NO to Engine Control 12 volts dc present gt switch
16. 1 X x xx v15 6000 0000 2 x 2 20137 R1 R2 3 x POWER a 4 WINDANG 5 x e gt mer Yt Wi 94 AUX POWER WHILE R13 22 WELDNG ONLY 9 37 A apt y 35 m V18 5 LOCK DL MEUM 42 CR2 SWITCH NO ee OFF 9 V41 RES 5 4 METER V1 2 ns as 2 V13 R12 i Throttle 5 ese Pct control relay so 2 VOLT Y ENTON DLE BOARD CR2 energized S A 2 2 za at weld rpm ALTERNATOR 05 cst 8 yor RECT 22 d le Field current TI TI TI TI TI SB control relay CR3 ia 32 R and auxiliary power V19 R18 NED control relay CR4 energized at See Section 6 5 power idle rpm for PC1 data TM 428 Page 18 Miller Legend Amperage Readings no warm up no load a Tolerance 5 unless specified b Condition 70 F 21 C cold machine 11 12 1 8 amps dc R1 at min Voltage Readings 3 1 amps dc R1 at max a Tolerance 10 unless specified b Condition 70 F 21 C cold machine no warm up no load
17. 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 Re 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 R1 if necessary see Section 3 1 Disconnect leads 22 and 29 from SCR integrated rectifier SR2 and check for continuity between leads 22 and 29 Replace exciter stator if necessary For units with optional remote control check capacitor C5 for a short or open and check for proper 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 55 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 1096 Replace R1 if necessary Disconnec
18. c Reference to circuit common lead 33 unless noted 521 g d Wiring Diagram see Section 9 33 N ups V1 DC CC OCV at weld rpm 58 volts dc R1 at min Ed 5 g 70 volts dc R1 at max lan N Do not exceed 72 volts dc rh u V2 AC CC OCV at weld rpm GFCI RECEPTACLE OPTION 65 volts ac R1 at min 80 volts ac R1 at max RUN Do not exceed 80 volts ac 57 E 68 a V3 At RC3 at power idle rpm 54 VOR m 244 volts ac 5 50 or 60 Hz ae RCI V4 At RC2 at power idle rpm EN 122 volts ac 5 50 or 60 Hz 23 R5 5 V5 At RC1 at power idle rpm 3 AUX 55 CB 9 122 volts 5 50 or 60 Hz WONG won V7 33 080000 JR4 57 V6 AC input to transformer T1 122 volts ac 5 3 en power idle rpm 0 volts ac weld rpm REVOLVNG FELD RESULATER os E V7 AC output to PC2 21 volts ac 5 RC1 PLG1 gt 33 5 b va V8 AC output to PC2 21 volts ac 5 29 Sections 67 V9 AC output from Regulator Power REGULATOR Windin ower idle rpm POWER WRONG thru 6 9 for PC2 data VORB R11 V9 R9 cz V3 V10 AC output from Weld Winding at z AW 57 CB5 weld rpm 65 volts ac R1 at min 80 1 volts ac R1 at max Do not exceed 80 A 52 volts ac 55 w 810 fe V11 At rated DC weld load At least 58 1 volts ac LX LA REN V12 At weld rpm 100 watt light bulb load 4
19. 12 Optional Remote Control Board PC3 Test Point Values a Tolerance 10 unless 5 specified PC3 Voltage Readings b Reference to circuit com mon lead 33 unless noted oo WE 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 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 O 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 28 Miller Legend 6 13 Optional Remote Capacitor Board PC5 Testing Information Effective With Serial No KD346698 Be sure plugs are secure before testing See Section 6 14 for spe cific values during testing 1 Capacitor Board PC5 2 Remote 14 Receptacle RC1 3 Receptacle RC2 4 Terminal K Ref S
20. 1P 25A 250VAC Prior to KE629034 2 2 CB5 7 168 057 CIRCUIT BREAKER man reset 1P 20A 250VAC Eff w KE629034 2 Deren 113 315 PANEL front Prior to JK713332 1 E 130 352 PANEL front Eff w JK713332 thru KB133271 1 OA len whan end 143 383 PANEL front Eff w KB133272 thru KF790319 1 170 554 PANEL front Eff w KF790320 and 1 4 S5 005 563 SWITCH selector Figure 10 4 1 R1 081 712 RHEOSTAT WW 100W 30 ohm 1 6 S4 44011609 SWITCH 19 SPDT 15A 125VAC Prior to JK713332 1 6 S4 011 611 SWITCH tgl DPDT 15 125V Eff w JK713332 1 7 RC7 035 523 CONNECTOR circ MS MET 5skt sz 16S rect MS 3102A 16S 8S Amphenol Prior to 713332 1 Figure 10 4 ST 115 943 J Figure 10 3 Panel Front w Components TM 428 Page 56 Miller Legend Item Dia Part No Mkgs No Description Quantity Figure 10 3 Panel Front w Components Figure 10 1 Item 43 Continued dat D ade 039 273 CONNECTOR circ MS MET 5 pin sz 16S MS 3106A 16S 8P Amphenol Votes ciet 039 685 CONNECTOR circ MS MET clamp str rlf sz 16 16S AN 3057 8 Amphenol 7 RC7 086 022
21. 5 y oo 02 applied 3 volts ac or greater 32 V13 Idle Lock switch S1 in Lock i 08 0 volts ac at all times Pr as V14 AC output from Exciter Winding COM 122 4 m 80 volts ac power idle rpm xg zm ks M 145 volts ac weld rpm d E MEN SOME V15 At RC4 at weld speed at least 120 9 bu pos volts ac Do not exceed 132 volts ac See Section 5 for N V16 Auxiliary power winding at weld rpm PC4 information at least 120 volts ac Do not exceed V2 C D V1 A B 132 volts ac V17 Auxiliary power winding at weld rpm i at least 120 volts ac Do not exceed Athra D 132 volts ac V18 Battery output whenever engine is running 14 volts dc V19 AC Alternator output 17 volts ac power idle rom 39 volts ac weld rpm SC 168 053 A Miller Legend TM 428 Page 19 6 3 Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control Resistance Values a b c Tolerance 1096 unless specified Condition 70 F 21 C cold machine no warm up Wiring Diagram see Section 9 Test Equipment Needed
22. 9 2 Circuit Diagram For Miller Legend Without Remote Control Effective With Serial No KE629034 And Following Miller Legend D5 gt 37 05 NEG ENGNE FOOT 5 Gi POS SOLENOID 4 BATTERY A T SE 494 1 50 20 u 8 B5 Kbps 5 8 89 G 0 0 5 43B PC1 G OL N AOS OOS 33L IT E RED T t m ENTON T 4 BLK CONTROL n 11 FIG H J K ALTERNATOR STATOR R 01 91 1212917121 19 MOUNTED BEHND BLOWER WHEEL 4 d 99 111 2 5 zn iu amp a 3 IE r g 023 4 OQ B EO 8 42A RC5 5 58 CONDENSER 5 9 4 3OA RCS G mis CR3 20 ONAN gt 2 ES 1 2 ENGINE D6 2 3044 2858 5 6 2 CR2 IA
23. Information 7 revor 14 Socket Socket Information A Contact closure to B completes 15 volts dc contactor control circuit 15 volts dc C 4 5 volts dc output to remote control D Remote control circuit common A E 0 to 4 5 volts dc input command signal from remote control K Chassis common ST 140 092 B The remaining sockets are not used TM 428 Page 6 Miller Legend 3 1 SECTION 3 OPERATING WELDING GENERATOR Front Panel Controls wl Ld DO NOT SWITCH UNDER LOAD 55 75 70 105 Using Idle Lock Switch RUN IDLE 1860 rpm 2 LOCK Power Idle RUN IDLE No Load lt gt 1860 rpm a gt Power idle C Load UNLOCK 3000 rpm Weld RUN fg cS OR eo 3000 rpm Weld UNLOCK LOC 1 Engine Control Switch S2 Use switch to start engine select speed and stop engine In Run ldie 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 2 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 3 Engine Choke Control Use control to change engine air fuel mix To Start pull out choke and turn Engine Control switch to Start positio
24. LE 5 im i 133 x 4 ev 313915 i x 5 141 504 H 094 en NOLLJ3NNOJ 9 DE 3709 193030 coy V 1 LH woo gt 96 8 sen g 9574 1 1 2 Y lt 80 NOH uw HOLMS an 10 55 2 5 D v ox jet lt v 780 L L 5 M X J 4 16 85 1 INS 5 z AND 5 FIHM XIV T L L 25 22 lt lt MZ OOD x 9 M 2 04 7 z OO x x SNICNM ag x a all 2 coy p Cm 19409090 A 8 9 ff 190 12 E t I x gt 65 NOLVTTERI 0194 9NIATOA3N 513 d 5 Y Y gt lt lt M 0000000000 370 t r osi r mm ea 3i 24 a WM ee wy 00 lec 2 z AN e 9 X M E n 21 Z 8 LE Bb OG gt 6 1 8 be o o n m s eo yor H 9 0 2 8 V 138 u LE z SJ z NA 67 ZZ 41 rre SZ lt sz 3 X M GE NOLLdO 310 143 38 1249 uH Tz z 55 jeg a 2 08 N 22 2 N 42 44 Su AL 79 1 045 TM 428 Page 43 Figure
25. Miller Legend TM 428 Page 31 6 16 Checking Unit Output After Servicing Check engine speeds and adjust if necessary see Section 8 5 1 115 VAC 100 Hz Receptacle RC4 With no load applied and engine running at weld rpm there should be 128 to 132 volts ac present at RC4 2 Slider 3 Resistor R4 Stop engine before adjust ing R4 If necessary adjust slider on R4 until 128 to 132 volts ac is obtained at RC4 Do not exceed 132 volts ac 4 DC Weld Output Terminals Turn Fine Amperage control R1 to max With no load applied and en gine running at weld rpm there should be 70 to 72 volts dc present at dc weld terminals 5 Resistor R2 Stop engine before adjust ing R2 If 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 Pre Operational Checks Wipe engine surfaces clean Check labels replace labels that are unreadable or damaged Check fuel and oil see Section 2 4 Check and correct any fluid leaks Clean weld output and battery terminals Tighten connections Clean outside of entire unit Tools Needed Ref ST 800 698 A ST 800 249 TM 428 Page 32 Miller Legend SECTION 7 DISASSEMBLY AND
26. Pacemaker wearers keep away from servicing areas until consulting your doctor 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 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 UNCONTROLLED TILTING OR TIPPING OF UNIT can result in personal injury and equipment damage Do not put any body part under unit while lifting 1 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 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 Useonly genuine MILLER replacement parts 4 Reinstall injectors and bleed air from fuel system according to engine manual 1 3 EMF Information Considerations About Welding And The Effects Of Low Frequ
27. REASSEMBLY Disassembly Of Unit 7 1 a combination of these compo trouble is in rotor stator engine or nents Use Section 6 1 to determine if Kunz unit Disconnect negative bat tery cable from battery Remove spark plugs Mark and disconnect all stator leads not damage rotor or sta Remove sheet metal panels from tor during this procedure move the engine generator as Use hoist and lifting strap to re sembly Tools Needed 3 8 7 16 1 2 9 16 in ST 800 710 A TM 428 Page 33 Miller Legend 7 2 Disassembly Of Generator 724 Poo WANE aw Hardware may differ from that shown Torques Prior To Serial No KD523655 Effective With Serial No KD523655 15 ft 20 N m A 15 ft Ib 20 N m B 30 ftIb 41 Nm B 20 ftlb 27 C 25 ft Ib 34 N m C 25 ft Ib 34 N m D 15ftlb 20 Nm D 20ftlb 27 E 15ftlb 20 Nm 15 20 Nm ST 115 942 F Do not damage stator or rotor wind 6 Fan Rotor Adapter 16 Brush Holder ings during this procedure 7 Rotor Fan Reassembly Disassembly 8 Rotor Reinstall t With engine properly supported with blocks engine an s Ur Patton remove hardware securing stator to engine 9 Bearing needed see torqu
28. proof bags to store move or ship PC boards STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin 1 Check coolant level when engine is cold to avoid scalding 2 If the engine is warm and checking is needed follow steps 3 and 4 3 Wear safety glasses and gloves and put a rag over cap 4 Turn cap slightly and let pressure escape slowly before completely removing cap ENGINE EXHAUST GASES can kill 1 not breathe exhaust fumes 2 Use in open well ventilated areas or vent exhaust outside and away from any building air intakes FALLING EQUIPMENT can cause serious personal injury and equipment damage 1 Use equipment of adequate capacity to lift components 2 Use a lifting eye to lift unit only NOT running gear gas cylinders or any other accessories 3 Securely attach components to lifting equipment Miller Legend TM 428 Page 1 HOT PARTS can cause severe burns Allow cooling period before servicing ELECTRIC SHOCK HAZARD incorrect use of test equipment from 1 2 Wear protective gloves and clothing when working on a hot engine 1 Stop engine before making or changing meter lead connections ay ZN 2 Atleast one meter lead should be a self retaining spring clip such as an alligator clamp 3 Readinstructions for test equipment MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation e N 1
29. spilled fuel MOVING PARTS can cause injury 1 Keep away from moving parts such as fans belts and rotors 2 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 3 Keep hands hair loose clothing and tools away from moving parts 4 Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting 5 Block flywheel so that it will not turn while working on generator components 6 Reinstall panels or guards and close doors when Servicing is finished and before starting engine 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 not use welder to charge batteries or jump start vehicles 5 Observe correct polarity and on batteries BATTERY ACID can BURN SKIN 1 Do nottip 2 Replace damaged battery 3 Flush eyes and skin immediately with water FLYING PIECES OF METAL or DIRT can cause injury 1 Always wear safety glasses with side shields or face shield during servicing 2 Becareful 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
30. 120 5 10 15 20 25 30 35 40 AC POWER AMPERES AT 240V SB 115 571 TM 428 Page 10 Miller Legend 4 3 60 Hz Auxiliary Power Receptacles And Circuit Breakers Fou N 120 N gt TOTAL ALL LOADS 5000 WATTS If unit does not have GFCI recep tacles use GFCl protected exten sion cord 1 120V 15A AC Duplex Receptacle RC1 2 120V 15A AC Duplex Receptacle RC2 3 240 V 30 Twistlock Receptacle 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 4 120V 15A AC Duplex GFCI Recep tacles GFCI1 And GFCI2 Optional If a 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 EF At least once a month run engine at power idle speed and press Test button to verify GFCI is working properly 5 Circuit Breaker CB5 6 Circuit Breaker CB7 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
31. 3000 RPM DC WELD AMPERES 100 DUTY CYCLE 0 1 5 2 0 2 5 5 0 3 5 4 0 4 5 5 0 POWER KVA AT 100 DUTY CYCLE SB 115 572 2 4 Engine Prestart Checks Check all fluids daily Engine must be cold and on a level surface Engine stops if oil pressure gets too low ST 140 091 E Ref ST 151 983 TM 428 Page 4 Miller Legend 2 5 Connecting The Battery Connect cable last Tools Needed I 3 8 1 2 in Ref ST 144 839 F Ref ST 168 046 Ref S 0756 D 2 6 Connecting To Weld Output Terminals gis Use ONLY one set of termi nals at a time Disconnect weld cables from set of weld output terminals not in use Tools Needed S 3 4 in ST 140 092 B Ref ST 168 046 Miller Legend TM 428 Page 5 2 7 Selecting Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding DH 085 005 E NC EUN 19 1008 Duty ve 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 AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere S 0007 D 2 8 Remote 14 Receptacle RC1
32. 5 Energizes when voltage is present in exciter stator to disconnect field flashing circuit 7 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 9 Current Transformer 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 Transformer 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 13 Remote Control Switch S4 Remote 14 12 12 Capacitor Board Remote PC5 And Remote 14 Control Board Receptacle RC1 PC3 Voltage Regulator Board PC2 18 Fine
33. 60 074026 RESISTOR C 25W 150 ohm 1 xdg R61 138301 POTENTIOMETER cermet 1 T 5W 25K ohm 1 2 4 R66 093030 RESISTOR MF 25W 15K ohm 1 viis R67 093032 RESISTOR MF 25W 26 7K 1 UIN R68 108437 RESISTOR MF 25W 4 75K 1 M 69 049439 RESISTOR C 2W 47K 1 re R70 074099 RESISTOR 150 R71 030707 RESISTOR 47 RC1 160892 CONNECTOR rect 9 pin row 11 cs VB50 108977225 1G tgltr 781b i ete uU an Reese SA 160 889 Figure 10 7 Circuit Card Voltage Regulator PC2 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Miller Legend TM 428 Page 61 Notes Notes
34. 60 545clp dia 2 162 ERES 066 113 FILTER fuel inline 250 included w engine 1 Ed CLAMP hose 460 545clp dia included w engine 2 18 ime sheets HOSE nprn SAE 250 ID included w engine order by ft 1ft 135 627 ENGINE gas elect start Prior to KG037344 consisting of 1 bens 178479 ENGINE gas elect start Eff w KG037344 consisting of 1 es eet rc 113 251 FITTING pipe brs cap 375NPT Prior to KF933389 1 nE 113 250 FITTING pipe galv nipple L 375NPT Prior to KF933389 1 oue 165 271 VALVE oil Eff w KF933389 1 Duca discite ees 107 297 MUFFLER exhaust engine Prior to 926822 1 EM 164 353 MUFFLER exhaust Eff w KF926822 1 BEER D 106 977 SOLENOID 12VDC 20 1 FREE 113 563 BRACKET mtg solenoid Prior to JK595850 1 CX roba 128 534 BRACKET mtg solenoid Eff 595850 1 128 869 LINKAGE KIT Prior to 404117 1 mr perpe 128 431 SWIVEL in line 250 28 Eff w JJ404117 1 128 533 LIN
35. 9 NUT stl hex full fnsh 500 13 1 R a 073 756 STAND OFF No 6 32 x 625 lg x 250 hex w KD344394 2 EURER 153 501 HOUSING PLUG amp SOCKETS w KD344394 consisting of 1 147 995 CONNECTOR rect univ 0395 22 18 6 28 C6 115 109 CAPACITOR Prior to KD344394 1 28 148 021 CIRCUIT CARD filter HF Eff w KD344394 1 7297 111 584 CONTROL push pull Prior to 283238 1 295 iis nist ios 116 813 CONTROL push pull 283238 1 NC EN 119014 LEVER switch rs en 1 Mo mr 108 864 CAP dust connector 9760 16 Prior to 713332 1 VES ea 109 993 CAP dust connector 9760 20 Eff wJK713332 1 097 924 KNOB Pointer us aussen REIR DESEE RE des 1 3599 010 647 PIN spring cs 156 x 1 250 1 ve dabis ame 021 385 BOOT tgl switch lever 1 Soke act EIER SEEN 115 493 HANDLE switch range 1 Part of Remote Control Option Effective w KD548030 Optional Meter Kit b
36. Air Cleaner Do not run engine without air cleaner or with dirty ele ment Stop engine 1 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 aircleaner3 1 96 ST 156 852 S 0759 Miller Legend TM 428 Page 37 8 4 Changing Engine Oil Oil Filter And Fuel Filter mA gt x C lal Stop engine and allow to cool 1 Oil Drain Valve 2 1 210 12 Hose 3 Filter Change engine oil and filter ac cording to engine owner s manual Close 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 5 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connections as necessary and wipe up fuel Tools Needed Se ST 140 091 E ST 144 840 C Ref ST 168 046 ST 800 395 S 0842 TM 428 Page 38 Miller Legend 8 5 Adjusting Engine Speed Rear View Tools Needed qo e 1860 rpm Power ldle 3000 r
37. CONNECTOR circ MS MET 14skt sz 20 MS 3102A 20 27S Eff w JK713332 thru KD344393 1 109 766 CONNECTOR 14 MS sz 20 Amphenol 97 4106 20 27 icis 109 770 CONNECTOR circ MS pin push in 16 22ga 039 734 CONNECTOR circ MS MET clamp str rif sz 20 225 Amphenol AN 3057 12 7 PC5 156 025 CIRCUIT CARD connector receptacle Eff w KD344394 1 Lagar eb 7 11 097 749 CAPACITOR Eff w JK713332 thru KD344393 5 8 2 ST 011 622 SWITCH tgl 15A 125VAC Prior to JK713332 1 8 ST sus 011 611 SWITCH tgl DPDT 15A 125V Eff w JK713332 1 1725070 erste 1 10 083432 CIRCUIT BREAKER man reset IP 10 250V 1 601 836 brs hex jam hvy 250 20 3 LED 010 915 WASHER flat brs 250 ID 625 OD 2 iaa ethos 083 030 STUD brs grd 250 20 x 1 750 1 Tann 042 130 METER KIT Prior to KD548030 consisting of 1 CE 2 032 936 METER oraret cers ata eate cde reb eins 1 DD 145 247 METER hour 12 24VDC Eff w KD548030 1 15 CB1 2 144 474 CIRCU
38. Control Board Module PC1 7 79 ES LE Engine does not go to weld rpm with Engine does not go to power idle rpm with no weld load applied load applied Connect meter AC between Connect meter DC between terminal G and terminal E terminal B and terminal E Start engine Place Engine Control Start engine Place Engine Control switch S2 in position Idle switch S2 in Run Idle position Lock switch S1 in Unlock position Check connections NO id 2 NO to Engine Control oad such as 12 volts dc present switch S2 and 2 0 zero volts ac present shorted diode in ground connaction main rectifier SR1 lead 33 YES YES Connect meter DC between Connect meter AC between terminal D and E terminal G and terminal E NO Check connections Start engine Place Engine IPSE d Ozero Gc present to Engine Control Control switch in Run ldle position switch S2 YES Connect meter DC between Connect a 100 watt light bulb to terminal C and terminal E 100 Hz ac receptacle NO Check connections 0 zero volts dc NO Minimum of 1 volt ac present e to current present after 12 to 18 seconds oa transformer CT1 YES
39. D 135 628 Removed F2 KA870084 thru KD346697 137 000 D 136 855 D Added S1 KD346698 thru KD438828 157 770 D 157 767 Added PC4 PC5 KD438829 thru KD548029 C 162 148 D 162 146 Added stator lead 33 KD548030 thru KE604175 166 823 D 166 822 Hourmeter standard KE604176 thru KE629033 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 JH242114 thru JH300533 SC 115 947 A mote Control JH300534 thru JJ420470 C 118 207 Changed PC1 and 51 add ed D5 JJ420471 thru JK713331 C 123 088 Be Added D6 JK713332 thru KA780043 C 130 928 Removed S1 KA780044 thru KA870083 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 162 147 Added stator lead 33 KE604176 thru KE629033 167 402 Hourmeter standard changed PC2 KE629034 and following SC 168 054 A Added CB5 CB7 D8 GFCI Circuit Board PC1 JH242114 thru JH300533 SB 113 710 Circuit Board PC2 JH242114 thru KE604175 049 506 KE604176 and following SB 160 891 Circuit Board PC3 JH242114 thru KA840709 115 891 KA840710 and following SB 136 249 Circuit Board PC4 KD346698 and following SA 148 024 A Circuit Board 5 KD346698 and following SB 156 027
40. IT BREAKER man reset 1P 25A 250VAC Eff w KE629034 2 16 RC3 604 103 RECEPTACLE str dx 2P3W 15 250V Prior to JH300534 1 Anh one 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 15A 125 1 N EEE EEE t 073690 PLUG str grd armd 2P3W 15A 125V P amp S 5266 DF TO some eei EEE NAMEPLATE order by model amp serial number 1 19 POS 039 047 TERMINAL pwr output red consisting 1 20 NEG 039 046 TERMINAL pwr output black consisting of 1 099 255 TERMINAL pwr output neutral consisting of 2 BADER EEE 601 976 SCREW cap stl hex hd 500 13 x 1 500 1 23 039 049 TERMINAL BOARD 1 039 045 TERMINAL BOARD black 1 29 7 SEM uu 039 040 TERMINAL BOARD 1 de rrt si ud 601 880 NUT stl hex jam 500 13 1 iD acc pe 039 044 BUS BAR term bd 1 601 87
41. K throttle 2404117 1 064 646 SPRING high speed 1 este ete een 137 046 TUNE UP amp FILTER KIT consisting 064 617 ELEMENT air cleaner 1 065 251 oen see ee es Ha 121 652 FILTER CLAMPS 1 DUNS La dnd 065 7095 SPARKPLUG 2525 ies vente os Durus EDS Peewee bh Soong gate Miller Legend TM 428 Page 53 Item Dia Part EA Mkgs No Description Quantity Figure 10 1 Main Assembly Continued T Leni dtt 107 308 HOLD DOWN bat Prior to KB113874 1 el kir 146 697 HOLD DOWN bat Eff w KB113874 thru KF959176 1 165 631 HOLD DOWN bat Eff w KF959177 and 1 010 493 BUSHING snap in 625 ID x 875mtg hole Prior to KA780148 2 Bien 165 630 BOLT J stl 250 20 x 6 125 959177 1 168385 LABEL warning battery 1 Labo ah E eec 115 511 BRACKET support cover Prior to KF812089 2 107 270 DOOR access bat
42. MINAL female 1skt 18 24 10 SB 116 028 Figure 10 6 Remote Control Option See Figure 10 3 for additional parts not listed BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS TM 428 Page 60 Miller Legend Dia Par Mkgs No Description Quantity PC2 160 888 Figure 10 7 Circuit Card Voltage Regulator Figure 10 5 Item 4 MM A50 165411 IC linear 2904 uet C1 003530 CAPACITOR cer mono 1uf 50VDC 1 ee 50 119 199 CAPACITOR polye met film 1uf 50V uae C51 053992 CAPACITOR cer disc 001uf 1000 1 52 000348 CAPACITOR tantlm 47uf 35V 11 53 005023 CAPACITOR tantlm 2 2uf 20V ELE 54 072935 CAPACITOR 33uf 35VDC tee sins 55 137463 CAPACITOR polye met film 22uf 100VDC 1 NEIN C56 072 113 CAPACITOR tantlm 4 7uf 35VDC m 57 028292 CAPACITOR cer disc 005uf 1000 00 1 mr 050 028351 DIODE sig 200mA 75V SP 1 bb D51 049641 DIODE
43. PC2 and connections and replace if necessary see Section 6 9 C 100 Hz Auxiliary Power Trouble Remedy No 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 16 Miller Legend 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
44. RE RS 8 8 3 g 1 seo H 4 155 gos 7B smM B 8 5 94 4 25A PLG1 9 8 gt 28A 2 24B RI T R2 G amp lt 2 88 O 8 8 8 NEG 2 16 55 2 Qd 15 55 EN 5 AC Z SR1 9 POS 2 J SD 168 051 B Miller Legend TM 428 Page 45 AWNOT1d0 504 SNIONIM Q I34833M0d SNIONIM 0934 358 Zod 1 S9NIONIM 33119X3 S9NIONIM S9NIONIM SNOILONYISNI LIJ 97313 39 128 O So 340 34 SC 115 947 Miller Legend O N HOLIMS 381055389 710 01 03507 X Effective With Serial No JH242114 Thru JH300533 f 92 90 12 12 12 Figure 9 4 Circuit Diagram For Miller Legend With Remote Control TM 428 Page 46 lt 5 NM ca 2 as p 230 N d NE lt 159 ISL E 90 WNO1dO er 8 auos NOLLINSI gt 187 od ov E be 508 SOd 1938 C 8 oc Le 7 ONHOUMS L lt gt 10 9 anes 10 __ am es 542 OH 9149
45. S2 and ground connection lead 33 YES Connect meter DC between terminals C and E NO Replace idle 12 volts dc present gt board module PC1 YES YES Check circuit breaker CB4 throttle solenoid TS1 connections and linkage and control relay CR2 Reinstall cover Check control relays CR3 andCR4 Reinstall cover Miller Legend TM 428 Page 25 6 7 Voltage Regulator Board PC2 Testing Information Prior To Serial No KE604176 Be sure plugs are secure before 2 1 testing See Section 6 8 for specif ic values during testing ms 9 O 1 Voltage Regulator Board PC2 2 Terminals A Thru G 7 65 LU 7 L O AP 52 8 bir A Test Equipment Needed N Ref ST 800 698 A SA 099 497 B 6 8 Voltage Regulator Board PC2 Test Point Values Prior To Serial No KE604176 gt a Tolerance 10 unless 5 specified RS PC2 Voltage Readings b Reference to circuit com mon lead 33 unless noted w Receptacle Value A Circuit common B 18 volts ac input with respect to pin A C 18 volts ac input with respect to pin A D Circuit common E 130 volts ac input with respect to terminal G at power idle rpm F 55 volts dc output with respect to terminal D at power idle rpm G 130 volts ac i
46. S3 should close when engine is running Check continuity of Engine Control switch S2 and replace if necessary Battery discharges between uses Make sure Engine Control switch S2 is placed in the Off position when engine is not in use see Section 3 1 Prior to Serial No KA780044 check fuse F2 and replace if necessary Clean battery terminals and posts with baking soda solution rinse with clear water Periodically recharge battery approximately every 3 months Check voltage regulator according to engine manual Replace battery Engine idles but does not come up to weld speed Wait 10 seconds for throttle solenoid circuit breaker 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 necessa
47. T 800 698 A SA 156 026 C 6 14 Optional Remote Capacitor Board PC5 Test Point Values Effective With Serial No KD346698 a Tolerance 10 unless 77 specified lt PC Voltage Readings b Reference to circuit com 2 mon lead 33 unless noted W zf Receptacle Pin Value RC1 A Contact closure to pin B completes the dc contactor control circuit B 15 volts dc output C Command reference 4 5 volts dc output D Remote control circuit command E Input command signal from potentiometer wiper 0 to 4 5 volts dc input K Chassis ground lead 33 RC2 1 Remote control circuit common 2 Command reference 4 5 volts dc input 3 15 volts dc input 4 Command signal from potentiometer wiper 0 to 4 5 volts dc output 5 Not used 6 Contact closure to pin 3 completes contactor control circuit Terminal K Chassis ground lead 33 Miller Legend TM 428 Page 29 6 15 Replacing Brushes And Cleaning Slip Rings A Checking Brushes And Cleaning Slip Rings ar Stop engine and allow to cool 1 Brush Holder Retaining 2 Brush Holder Bracket Remove brush holder bracket Keep hardware for reinstallation 3 Brush Holder 4 Brush With Spring 5 Brush Holder Cap Mark and disconnect leads at caps and remove brushes from bracket Replace brushes if damaged or if brush is at or near minimum length 6 Slip Rings I
48. al Remote Control Board PC3 Effective With Serial No KA840710 And Following GND SB 148 024 A Figure 9 9 Circuit Diagram For HF Filter Board 4 Effective With Serial No KD346698 And Following Miller Legend TM 428 Page 49 RC2 RC2 RC2 RC2 RC2 TM 428 Page 50 RC1 RC1 RC1 9 A e wn REMOTE COMMON REMOTE REFERENCE REMOTE WIPER 249 AC DC CONTRCTOR CONTROL 24U RC DC CONTRCTOR SUPPLY CHRSSIS GROUND SB 156 027 Figure 9 10 Circuit Diagram For Optional Capacitor Board PC5 Effective With Serial No KD346698 And Following Miller Legend m February 1996 Form TM 428 Effective With Serial No JH242114 SECTION 10 PARTS LIST Miller Legend Formerly The Legend AEAD 200LE CC AC DC Welding Generator For SMAW GMAW GTAW Welding Miller Legend TM 428 Page 51 A quiessy ulen 1 01 o4nDiJ 9 01 4 9 01 en i4 jJ 5 01 9 er ie Miller Legend TM 428 Page 52 Item Dia Part No Mkgs No Description Quantity Figure 10 1 Main Assembly a dtes 44042 132 REMOTE CONTROL Figure 10 6 Prior to JK713332 1 dum 042 383 REMOTE CONTROL Figure 10 6 Eff w JK713332 1 Wu ps eR ER Figure 10 5 CONTROL PANEL w components 1 v DIE 113 302 UPRIGHT b
49. an P218 Eff w KF959177 and on 1 22 8 113 410 GUARD fan 1 RAE rire 153 297 ENDBELL gen consisting of 1 BAD tn kta 143220 O RING 2 859 ID 139 5 1 T 165 756 STATOR gen 60Hz Prior to 438829 1 ou Diu 162 138 STATOR gen 60Hz Eff 438829 1 165 755 STATOR gen 50Hz Prior to 438829 1 xni sit iie 162 141 STATOR gen 50Hz Eff 0438829 1 017702 ADAPTER engine cece OPES EUG 1 ied onda habeis 003 455 KEY woodruff 250 x 750 SAE No 91 part of engine Prior to KA780148 1 021 934 ADAPTER fan rotor Prior to KA780148 1 E DEP 134981 ADAPTER fan rotor w KA780148 1 ene 008 917 WASHER flat stl 343 ID x 2 part of engine 1 EN 049 286 ROTOR ASSEMBLY gen consisting of 1 017 624 TOLOR gene ra BE A Bann 1 heist 053 390 BEARING ball sgl row 1 37 1 arat es 024 617
50. ase Prior to KA780148 1 qus 129 384 UPRIGHT base Eff w KA780148 thru KA892304 1 cR 136 057 UPRIGHT base Eff w KA892305 and 1 107342 SEALs Ifteye ie er TI TE s 1 iD Eos e Ehe 113 303 PANEE SIdO 12108 a TO pied e 2 B 113 304 COVER top Prior to JJ365634 1 ves Bo ois nerds 114 557 COVER top Eff w JJ365634 thru KF812088 1 m epp 173 209 COVER top 812089 1 DE Ei 120 304 BLANK snap in 250mtg hole Eff w JJ365634 thru KB133271 2 Du ES 143 397 BLANK snap in 312mtg hole Eff w KB133272 thru KF812088 2 pouf trs Z t cca 108 487 LABEL warning falling equipment etc 1 S use s aM 113 439 PANEL rear lower Prior to 780148 1 eds 128 789 PANEL rear lower Eff w KA780148 thru KA892304 1 BE EEE 136 059 PANEL rear lower Eff w KA892305 on 1 eO Lisa 095 970 STRIP nprn wsl eng firewall 18 2 TO y 088 731 BUSHING snap in 3751 1 11 PGB eet HOUSING part of engin
51. e table Remove generator parts as needed 10 Retaining Ring Reconnect fuel line choke cable and base 11 Integrated Rectifier 582 ground cable Reinstall spark plugs battery 1 Fan Guard 9 and tray panels and cover 2 O Ring 12 Brush Holder Bracket Use cable ties to secure leads in existing 3 13 Brush Holder Retaining Bar wiring harnesses and away from moving or 4 Stator Assembly 14 Brush Holder Cap hot parts 5 Engine Adapter 15 Brush Reconnect negative battery cable TM 428 Page 34 Miller Legend SECTION 8 MAINTENANCE 8 1 Routine Maintenance 9 95 Stop engine before maintaining on d x 4 See also Engine Manual and mainte ae nance label Service engine more often during severe conditions 8 Hours 3 lt Check Fluid PEE ra Levels OIL See Section 2 4 Full 20 Hours Check And Clean Spark Arrestor Screen G 25 Hours Clean And Check Air Cleaner 7 50 Hours Clean And Tighten Weld vit 2 Terminals e 100 Hours Change Oil See Chan E ge Oil Filter See xu 27 Section 8 4 And up ve Maintenance Label Clean Cooling Clean And System Tighten See Engine Battery Manual Connections 200 Hours WARNIN Check T ENJA Valve See Section gt Unreadable Clearance UM 8 4 Labe
52. e wiring harness PEDES 113248 TANK fuel Prior to KA780148 consisting of 1 015603 x cete cem er c ere d DERE 107 345 1135685 TUBES pick up uel eR d dbi ie pay Np 010 863 CLAMP hose 2 1 16 3 clamp dia Prior to KA780148 2 biu 107 346 HOSE fuel tank Prior to KA780148 ukasa uot oie e E 107 324 BRACKET support pipe filler Prior to 780148 1 107 343 GROMMET rubber neck filler fuel Prior to KA780148 1 113 486 COVER fuel tank Prior to 780148 E 113 392 HOLD DOWN fuel tank Prior to KA780148 1 ME EE 113 294 SUPPORT center mtg engine Prior to 780148 1 19 545 147 601 CAP tank screw on w vent 1 130 123 TANK fuel 7 5gal Eff w KA780148 thru KG037343 1 13 52 58 FIRE 177 606 TANK fuel 7 5gal Eff w KG037344 on 1 VA Ks 145 976 HOSE nprn SAE 250 ID 1 15 7532 54255203 PER 084 173 CLAMP hose 4
53. ecame Standard Equipment BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Miller Legend TM 428 Page 57 Item Par Description Quantity Figure 10 4 Switch Selector Figure 10 3 Item 4 No No 005 563 prr 005 562 At 005 561 005 564 a siete oe 605 276 Beo erus 005 559 005 560 d 008 485 Boi chan 005 566 9632 2265 011 644 1052 ts 052 405 052 404 s 005 557 005 558 BRACKET mtg switch SHAFT rotor INSULATOR SPACER contact switch CONTACT BOARD stationary switch CONTACT stationary switch SPRING pressure contact switch CONTACT movable switch BUS BAR switch range SPRING selector switch 3 screw switch SCREW cap stl hex hd 250 20 x 1 250 CONTACT BOARD movable switch CONTACT switch movable Figure 10 4 Switch Selector ST 097 264 A BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS TM 428 Page 58 Miller Legend Item Dia Par No Mkgs No Description Quantity Figure 10 5 Control Panel w Components Figure 10 1 Item 2 1T 038 601 BLOCK term 30A Prior to 713332 e DS TI ues 130 648 BLOCK term 30A 10 Eff 9 713332 vB sa ERR RR 113 682 BRACKET mtg components Prior to JK713332
54. ency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around the body 4 Keep welding power source and cables as far away as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers The above procedures are also recommended for pacemaker wearers Consult your doctor for comp
55. ip 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 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 Check continuity of coil and condition of con tacts Replace 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
56. jumper term 30A D6 117 566 DIODE rect 6A 600 4 ST 114 309 B Figure 10 5 Control Panel w Components BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Miller Legend TM 428 Page 59 Figure 10 7 Item Dia Par No Mkgs No Description Quantity 3015 263 Figure 10 6 Remote Control Option Figure 10 1 Item 1 1 136 246 CIRCUIT CARD ASSEMBLY remote control 1 Lai SERS mecs AES 110 375 STAND OFF SUPPORT PC card 4 n CR POE 116 086 BRACKET mtg remote control Prior to JK563388 1 ice RD ga dee git 125 873 BRACKET mtg remote control Eff 563388 1 4 CR5 052 603 RELAY 110VDC DPDT 1 gee RE 007 532 CLAMP capacitor 1 000dia 1 ver C5 059 887 CAPACITOR polyp met film 10uf 220V 1 Sel RIA BI zen 116 005 BLOCK term 10 7 1 E Ure ot eat 20 108 023 LINK jumper term blk 10 4 9 PLG6 115 091 HOUSING PLUG amp SOCKETS consisting 1 PORT TR 113 746 TER
57. king Unit Output After Servicing 32 WHO DO I CONTACT FOR HELP CALL FAX WRITE en Miller Electric Mfg Co P O Box 1079 Appleton WI 54912 USA Always provide Model Name and Serial or Style Number OM 428N 1 96 SPM 428C 6 94 SECTION 7 DISASSEMBLY AND REASSEMBLY 33 le Bisassembly Of Unit Sau rate ee a war e atr dci Pirates 33 7 2 Disassembly Of Generator 34 SECTION 8 MAINTENANCE 35 8 1 Routine Maintenance 35 8 2 Maintenance Label rette eoe te pe epic d t CER amare DU 36 8 3 Servicing Air Cleaner s nr TERR ee HUE as 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 etm nee C ee i Ek e ae 51 SECTION 1 SAFETY PRECAUTIONS FOR SERVICING 1 1 Symbol Usage
58. lete information TM 428 Page 2 Miller Legend SECTION 2 INSTALLATION 2 1 Installing Welding Generator Movement Airflow Location A Do Not Lift Unit From End 18in 460 mm 18 in 18 in 460 mm 460 mm OR 18 in 18 in 460 mm 460 mm Grounding 1 Generator Base 1 3 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 1 4 Grounding Cable OR Use 10 AWG or larger insulated copper wire Se A unit does not have receptacles use GFCI pro Electrically bond generator frame to Y 3 uA tected extension cord vehicle frame by metal to metal T 2 contact 2 install 10 95 Ref 5 800 652 Ref ST 800 477 ST 158 936 A S 0854 2 2 Dimensions Weights And Operating Angles Dimensions Do not exceed operating angles while Height 31 5 8 in 803 mm running or engine damage will occur Donotmove or operate unit where it could Width 18 in 457 mm tip Depth 45 in 1143 mm B A 16 1 2 in 419 mm B 32 3 4 in 832 mm C 13 16 in 21 mm Dia n Weight C Net 559 Ib 254 kg Engine End Ship 600 Ib 272 kg Miller Legend TM 428 Page 3 2 3 Fuel Consumption LITERS HR IMP GAL HR oU S GAL HR M M m gt N a 3 78 0 84 1 00 2 84 0 63 0 75 1 89 0 42 0 50 DC WELD 3000 RPM pra AC WELD
59. ls 500 Hours Repair Or Replace T Cracked Cables par Plugs Blow Out Or Vacuum Inside During Heavy Service Clean Monthly Miller Legend TM 428 Page 35 8 2 Maintenance Label TM 428 Page 36 ONAN P218 GAS ENGINE See Engine Manual for complete engine care Give engine Specification and Serial Number when ordering parts To Drain Oil Push And 7 Check Turn CCW daily 1 2 in ID Hose Recommended Oil API Service Classification SF SG SF CC SG CE Oil amp 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 Fuel Grade Regular or Unleaded Fuel Filter MILLER 066 113 Onan 149 2206 01 Fram G10E1 Air Filter Service 100 hours or less see Owner s Manual Air Filter Element MILLER 064 617 Onan 140 2522 Air Filter Wrapper MILLER 065 653 Onan 140 1496 12 Volt Battery BCI Group 58 Cranking Perform 430 Amps min Engine RPM No Load Power 1650 50 Hz 1860 60 Hz Weld 3000 Valve Clearance Cold In 0 005 in 0 13 mm Ex 0 013 in 0 33 mm Spark Plug Gap 0 025 in 0 6 mm Spark Plug Champion RS17YX Preferred or RS14YC Use only resistor spark plugs and wires Spark Arrestor Inspection And Service 20 operating hours see Owner s Manual S 176 891 Miller Legend 8 3 Servicing
60. n 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 5 Ampere Ranges Switch S5 FINE AMPERAGE Ref ST 168 046 Use switch to select weld amperage range EF For best arc starts use lowest amper age range possible 6 Fine Amperage Control R1 Use control to select weld amperage within the range selected by the Ampere Ranges switch Control may be adjusted while weld ing Scale is for reference only Weld output would be 88 A DC with control settings as shown 50 of 70 to 105 A 7 Engine Hour Meter HM Miller Legend TM 428 Page 7 3 2 Remote Control Optional Weld 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 to RC1 see Section 2 8 In Example Min 70 ADC Percentage Of Range 50 Max 88 A DC 50 of 70 to 105 Max 88 A DC Min 70 A DC Set Switch 2 Set Range n Set Percentage Adjust Remote Control ST 140 092 B 3 3 Duty Cycle RATED OUTPUT Duty cycle is the percentage of 10 minutes that unit can weld at rated load without ove
61. nator output waveforms A thru D 17 volts ac power idle rom 39 volts ac weld rpm SC 168 054 A Miller Legend TM 428 Page 21 6 4 Waveforms For Sections 6 2 And 6 3 2ms 50V gnd A DC Open Circuit Voltage Ampere Ranges Switch S5 In Max Position 5ms 50V gnd C AC Open Circuit Voltage Ampere Ranges Switch S5 In Max Position Waveforms shown are for 60 Hertz models waveforms for 50 Hertz models are similar 2ms 10V gnd B DC Weld Output 25 Volts DC 100 Am peres Ampere Range Switch S5 In 70 105 Position Resistive Load 5ms 20V gnd D AC Weld Output 25 Volts AC 100 Amperes Ampere Range Switch S5 In 70 105 Position Resistive Load A FA Test Equipment Needed TM 428 Page 22 Miller Legend 6 5 Idle Control Board Module PC1 Testing Information Be sure plugs are secure before testing See Section 6 6 for specif ic values during testing 1 Idle Control Board PC1 Prior To Serial No JH300534 2 Idle Module PC1 Effective With Serial No JH300534 Test Equipment Needed 2 Ref 57 800 698 A SC 113 702 A Miller Legend TM 428 Page 23 6 6 Troubleshooting Flowcharts For Idle
62. nput with respect to terminal E at power idle rpm TM 428 Page 26 Miller Legend 6 9 Voltage Regulator Board PC2 Testing Information Effective With Serial No KE604176 1 2 Be sure plugs are secure before testing See Section 6 10 for spe cific values during testing 1 Voltage Regulator Board PC2 2 Receptacle Test Equipment Needed Ref ST 800 698 A SA 160 889 A 6 10 Voltage Regulator Board PC2 Test Point Values Effective With Serial No KE604176 gt a Tolerance 10 unless 5 specified PC2 Voltage Readings b Reference to circuit com mon lead 33 unless noted 5 m Receptacle Pin Value RC1 E 18 volts ac input with respect to pin 5 Not used 18 volts ac input with respect to pin 5 Circuit common 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 A AJ OJN 55 volts dc output with respect to pin 4 at power idle rom Miller Legend TM 428 Page 27 6 11 Optional Remote Control Board PC3 Testing Information 1 Be sure plugs are secure before testing See Section 6 12 for spe cific values during testing 1 Remote Control Board 2 Receptacle Test Equipment Needed Ref ST 800 698 A ST 115 941 L SA 138 247 6
63. nspect slip rings Under normal use rings turn dark brown If slip rings are corroded or surface is uneven insulate brush leads start engine and clean rings with a commutator stone Remove as little material as possible Stop en gine Install brushes bracket and re maining generator parts Adjust brushes as shown in Section B Reinstall both side panels and top cover 5 16 in 8 mm Minimum Length la gt lt 96 in 14 3 mm New Length Replace Damaged Brushes Tools Needed W ST 800 698 A Ref ST 115 942 F S 0233 A TM 428 Page 30 Miller Legend B Adjusting Brush Position 3 32 in Correct Brush Position Incorrect Brush Position Stop engine After installing brushes adjust brush position as follows 1 Brush Holder 2 Brass Sleeve 3 Brush 4 Slip Ring Loosen brush holder bracket mounting hardware Move bracket until brass sleeves are positioned as shown Tighten hardware Reinstall side panels and cover If operation is still not okay have a qualified machine shop turn and polish slip rings Center brushes on slip rings Correct Brush Position Tools Needed 3 8 1 2 in Ref ST 800 698 A Ref ST 800 677 B
64. oad 17 100 Hz Auxiliary Power Re ceptacle RC4 Provides connection point and power for auxiliary equipment while welding 18 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 21 Main Rectifier SR1 Changes ac output from weld windings to dc 22 Stabilizer DC Z Smooths out current to dc weld output terminals 23 HF Filter Board PC4 Protects unit from high frequency 24 Positive And Negative DC Weld Output Terminals Provide dc weld output 25 Electrode And Work AC Weld Output Terminals Provide ac weld output Positive And AC Or DC Control Circuits Weld Current Circuit Mechanical Coupling Magnetic Coupling Optional Miller Legend TM 428 Page 13 NOTES TM 428 Page 14 Miller Legend SECTION 6 TROUBLESHOOTING 6 1 Troubleshooting Tables A Welding wa gt x See Sections 6 2 and 6 3 for test points and values and Section 10 2 Ch 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
65. olts ac 5 50 or 60 Hz 87 MT N V6 AC input to transformer T1 122 volts ac 7 12 R7 V8 cV5 power idle rpm volts ac weld rpm 20 NI R5 co 65 V7 AC output to PC2 21 volts ac 5 POWER POWER 7 O 77 72 57 WINDING IRA V8 AC output to PC2 21 volts ac 35 2 22 22 RC2 V9 AC output from Regulator Power MAE EINE m s NY Winding power idle rpm 122 5 v4 158 volts ac 5 V10 AC output from Weld Winding at WELD X G weld rpm 65 volts ac R1 at min 80 TR u volts ac R1 at max Do not exceed 80 V3 volts ac V10 R8 R11 V11 At rated DC weld load At least 23 See Sections 6 7 1 volts ac 5 thru 6 9 for PC2 data V12 At weld rpm and 100 watt light bulb load applied 3 volts ac or greater SR R10 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 5 145 volts ac weld rpm 15 At RC4 at weld speed at least 120 Pt 222 o_ volts ac Do not exceed 132 volts ac M 122 16 Auxiliary power winding at weld rpm at least 120 volts ac Do not exceed 132 volts ac ELECT WORK NEG AC Dc V17 Auxiliary power winding at weld rpm See Section 5 for at least 120 volts ac Do not exceed PC4 information 132 volts ac V2ICID V1 A B V18 Battery output whenever engine is running 14 volts dc See Section 6 4 for V19 AC Alter
66. pm Weld Top View 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 ldle position Turn Fine Amperage control to 100 1 Carburetor 2 Throttle Solenoid Power Idle Speed Adjustment 3 Power ldle Speed Rod 4 Lock Nut 5 Adjustment Nut Loosen lock nut and rotate adjust ment nut until engine runs at pow er idle speed Tighten lock nut Weld 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 Tighten lock nut 8 Weld Speed Governor Spring 9 Power ldle Speed Governor Spring If a spring becomes loose or dis connected reattach as shown 8 3 8 in 8 11 ST 116 049 C Miller Legend TM 428 Page 39 8 6 Overload Protection ER Stop engine 1 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 If F1 continue
67. preis energized at V19 See Section 6 5 power idle rpm TM 428 Page 20 Miller Legend Amperage Readings a Tolerance 5 unless specified b Condition 70 F 21 C cold machine no warm up no load 1 3 amps dc 12 1 8 amps dc R1 at min Voltage Readings 3 4 amps ge Pl at max 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 GFCI 1 z i V1 DC CC OCV at weld rpm B 58 volts dc R1 at min 33 70 volts dc R1 at max GS Do not exceed 72 volts dc V2 at weld rpm 65 volts ac R1 at min 33 N 80 volts ac R1 at max nh Do not exceed 80 volts ac co GFCI RECEPTACLE OPTION V3 At RC3 at power idle rpm 97 gt gt 244 volts ac 5 50 or 60 Hz CONNECTED PER FIELD 6 KIT NSTRUCTIONS V4 At RC2 at power idle rpm 82 88 gt 122 volts ac 5 50 or 60 Hz 54 52 V5 At RC1 at power idle rpm R6 V6 R3 A 122 v
68. rheating A Exceeding duty cycle can damage unit and void war ranty 300 250 225 200 150 WELD AMPERES 100 75 50 10 15 20 25 30 40 50 60 70 80 90 100 DUTY CYCLE 100 Duty Cycle at 225 Amperes AC Continuous Welding SB 115 570 TM 428 Page 8 Miller Legend 3 4 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of other settings fall between the curves shown 140 AC VOLTS AC AMPERES DC VOLTS DC AMPERES SB 115 529 A SB 115 528 A Miller Legend TM 428 Page 9 SECTION 4 OPERATING AUXILIARY EQUIPMENT 100 Hz Auxiliary Power Receptacle And Circuit Breaker 74 N RQ 2 Do not operate 50 60 Hz 60 Hz equipment from 100 j Hz receptacle 1 115 100 Hz AC Recep tacle RC4 Receptacle supplies single phase power at weld speed only Total output available is 1 2 Circuit Breaker CB3 CB3 protects receptacle from overload If CB3 opens receptacle does not work 15 9A 100HZ AC WHILE WELDING TOOLS AND LIGHTS ONLY CAUTION REFER TO OWNERS MANUAL Ref ST 168 046 4 2 AC Auxiliary Power Curve 260 130 240 120 o gt x zx 220 110 lt 200 100 10 20 30 40 50 60 70 80 AC POWER AMPERES AT
69. ry see Section 6 5 Engine does not return to idle speed Remove weld load Check continuity of Engine Control switch S2 and replace if necessary Check throttle linkage for smooth non binding operation Unstable or sluggish engine speeds Readjust throttle linkage if necessary Tune up engine according to engine manual Miller Legend TM 428 Page 17 Troubleshooting Circuit Diagram For Welding Generator Resistance Values a b c d Tolerance 10 unless specified Condition 70 F 21 C cold machine no warm up Wiring Diagram see Section 9 Stop engine before checking resistance R1 29 ohms R2 34 ohms R3 35 ohms R4 2 ohms R5 2 ohms R6 thru R17 Less than 1 ohm R18 Pull Less than 1 ohm Hold 16 5 ohms Test Equipment Needed See Section 6 16 for R2 and R4 adjustment 27 B E D J TO 9 2 5 5 S 38 27 54 537 y 49 48 37 33 23 gt Abs SPRINGS Back TO 444000 H l2 lt 512 REV FELD 2 u 00000 40000
70. s 3 2 3 Consumption s scd emerunt A 4 2 4 Engine Prestart Checks 4 2 5 Connecting The Battery 5 2 6 Connecting Weld Output Terminals 5 2 7 Selecting Weld Cable Sizes 6 2 8 Remote 14 Receptacle Information 6 SECTION 3 OPERATING WELDING GENERATOR 7 3 1 Front Panel Controls 7 3 2 Remote Control Optional 8 9 9 Duty Cycle SUL Le eoe bet e v lg 8 3 4 Volt Ampere Curves 9 SECTION 4 OPERATING AUXILIARY EQUIPMENT 10 4 1 100 Hz Auxiliary Power Receptacle And Circuit Breaker 10 4 2 Auxiliary Power Curve 2 senses aa ees pene 10 4 3 60 Hz Auxiliary Power Receptacles And Circuit Breakers 11 SECTION 5 THEORY OF OPERATION 12 SECTION 6 TROUBLESHOOTING
71. s to open check inte grated rectifier SR2 and rotor Tools Needed ST 152 264 A 8 7 Inspecting And Cleaning Optional Spark Arrestor Stop engine and allow to cool 1 Spark Arrestor Screen Clean and inspect screen Re place spark arrestor if screen wires are broken or missing FE Tools Needed 1 4 in nmm ST 140 091 E ST 801 206 Ref ST 168 046 TM 428 Page 40 Miller Legend SECTION 9 ELECTRICAL DIAGRAMS The following is a list of all diagrams for models covered by this manual To order a copy proceed as follows 1 Know unit Model and Serial or Style Number 2 Use this list to find diagram number 3 Include your FAX number or mailing address with your request 4 FAX Technical Publications Department at 414 735 4011 or call 414 735 4356 EF 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 Model Serial Or Style Number Dr sacar Miller Legend Without Re JH242114 thru JH300533 SC 114 477 A D 117 65144 mote Control JH300534 thru JJ420470 117 626 B D 123 101 Changed PC1 and S1 add ed D5 JJ420471 thru JK713331 C 123 087 B D 130 651 Added D6 JK713332 thru KA780043 SC 130 929 D 130 651 Removed S1 KA780044 thru KA870083 135 624
72. safety rtm1 4 95 Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols 9 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING 2 PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards A Marks a special safety message Means NOTE not safety related 1 2 Servicing Hazards WARNING The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons should service test maintain and repair this unit During servicing keep everybody especially children away ELECTRIC SHOCK can kill 1 Do not touch live electrical parts 2 Stop engine before testing or repairing unit unless the procedure specifically requires an energized unit 3 Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground 4 Donotleave live unit unattended 5 When testing live unit use the one hand method Do not put both hand inside unit Keep one hand free 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
73. t 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 Miller Legend TM 428 Page 15 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 str
74. tery Prior to KF959177 1 175 887 DOOR access battery Eff 959177 1 088 577 CABLE bat pos Prior to KF959177 consisting of 1 bete t 167 731 CABLE bat pos Eff w KF959177 included w engine consisting of 1 PP T 071 970 COVER cable bat post red 1 32 BAT 071 678 BATTERY stor 12V Prior to KF959177 1 32 BAT 168037 BATTERY stor 12V Eff wKF959177 1 uut hse pide poked 114 923 BOOT insulator term post red Prior to KA780148 1 p EIER A er 135 571 BOOT insulator term post red Eff w KA780148 thru KC220663 1 re 108 081 TERMINAL PROTECTOR battery post mtg 2 mE 020 279 CLAMP stl cushion 750 dia x 281mtg hole Eff w KA780148 2 II vie dts der k ss 107 753 CABLE bat neg Prior to KA780148 consisting of 1 RER 023 641 CABLE bat neg Eff w KA780148 thru KE668694 consisting of 1 au Dg dete eto tens 167 730 CABLE bat neg Eff w KE668695 consisting of 1 a gucken eeiam utaq 071 971 COVER cable bat post 1 PEL PPP Figure 10 2 GENERATOR clo whe
75. zener 27V 1W 1 DK D52 54 026202 DIODE rect 1A 400V SP ER 055 58 070250 DIODE rect 600V 4 T 059 030529 DIODE rect 22A 600V RP aera Q50 039355 TRANSISTOR ujt 15mA 40V 1 TT Q51 52 037200 TRANSISTOR NPN 200mA 40V 2 ENT 053 54 049642 THYRISTOR SCR 8A 600V 2 50 094447 RESISTOR MF 25W 681K ohm 1 Meer R51 044789 RESISTOR MF 25W 100K ohm 1 52 035829 RESISTOR MF 25W 1 5K ohm 1 R58 54 65 072559 RESISTOR 25W 22 1 3 RUP 55 115 530 RESISTOR MF 25W 2 67K 1 vit R56 64 000885 RESISTOR MF 25W 10K ohm 2 R57 62 028285 RESISTOR C 5W 100 2 PNE R58 63 035823 RESISTOR MF 25W 100 2 Meri 59 072559 RESISTOR MF 25W 224K 1 NE R
Download Pdf Manuals
Related Search