Technical Manual TM-428

February 1996 Form: TM-428
Effective With Serial No. JH242114
TECHNICAL MANUAL
Service And Parts
Miller Legend®
(Formerly The Legend™ AEAD-200LE)
CC AC/DC Welding Generator For SMAW, GMAW, GTAW Welding
Weld Rated Maximum

Welding Auxiliary Power
Output Welding Open-Circu Fuel Capacity Engine
Mode Rating
Range Output it Voltage
225 A, 25 V, Single-Phase,
CC/AC 35 – 225 A 100% Duty 80 5 kVA/kW, 42/21 A,
Cycle 120/240 V AC, 60 Hz Onan P218 Air-Cooled,
And 7 5 gal (28 L) Tank
7.5 Two-Cylinder, Four-Cycle,
200 A, 25 V, Single-Phase, Gasoline Engine
CC/DC 25 – 200 A 100% Duty 72 1 kVA/kW, 9 A,
Cycle 115 V AC, 100 Hz
cover_tm 4/95 – ST-140 091-E © 1996 MILLER Electric Mfg. Co. PRINTED IN USA
Downloaded from www.Manualslib.com manuals search engine

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 Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Dimensions, Weights, 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 Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-8. Remote 14 Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 – OPERATING 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 – OPERATING AUXILIARY 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 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
WHO DO I CONTACT FOR HELP?

CALL: FAX: WRITE:
Miller Customer Service 800-637-2348 (in USA), Miller Electric Mfg. Co.
Department at or P.O. Box 1079
414-735-4505 414-735-4136 (outside USA) 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
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

SECTION 2 – INSTALLATION
2-1. Installing Welding Generator
Movement Airflow Location
Do Not Lift Unit From End 18 in

(460 mm)
18 in
18 in (460 mm)
(460 mm)
OR
OR
18 in 18 in
(460 mm) (460 mm)
Grounding 1 Generator Base

1 3 2 Metal Vehicle Frame
4
GND/PE 3 Equipment Grounding
Terminal
4 Grounding Cable
OR Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI
receptacles, use GFCI-pro-
Electrically bond generator frame to tected extension cord.
vehicle frame by metal-to-metal
2 contact. 2
install1 10/95 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
2-2. Dimensions, Weights, And Operating Angles
Dimensions
A
Do not exceed operating angles while
Height 31-5/8 in (803 mm) running or engine damage will occur.
Do nott move or operate
D t unit
it where
h it could
ld
Width 18 in (457 mm) tip.
Depth 45 in (1143 mm)
B A 16-1/2 in (419 mm)
25°
B 32-3/4 in (832 mm)
25° 25°
C 13/16 in (21 mm) Dia.
25°
Weight
C
Net 559 lb (254 kg)
Engine End Ship 600 lb (272 kg)
Miller Legend TM-428 Page 3

2-3. Fuel Consumption
SB-115 572
2-4. Engine Prestart Checks

Check all fluids daily. Engine must
be cold and on a level surface.
Engine stops if oil pressure gets
1/2 in too low.
(13 mm)
Full
Full
ST-140 091-E / Ref. ST-151 983
TM-428 Page 4 Miller Legend

2-5. Connecting The Battery
Connect (–) cable last.
+ –
Tools Needed:
3/8, 1/2 in
Ref. ST-144 839-F / Ref. ST-168 046 / Ref. S-0756-D
2-6. Connecting To Weld Output Terminals

Use ONLY one set of termi-
nals at a time. Disconnect
weld cables from set of weld
output terminals not in use.
Tools Needed:
3/4 in
ST-140 092-B / Ref. ST-168 046

2-7. Selecting Weld Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Welding 10 – 60% 60 – 100%

10 – 100% Duty Cycle
Amperes Duty Cycle 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 (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D
2-8. Remote 14 Receptacle RC1 Information
Socket* 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.
A J D Remote control circuit common.

K
A
B I
C L N H
E 0 to +4.5 volts dc input command signal from remote control.
D M G
E F
K Chassis common.
ST-140 092-B
*The remaining sockets are not used.

SECTION 3 – OPERATING WELDING GENERATOR
3-1. Front Panel Controls
5 6 1 2 7
4
Using Idle Lock Switch
RUN/IDLE
1860 rpm
LOCK (Power/Idle)
RUN/IDLE No Load:
1860 rpm
(Power/Idle)
Load:
UNLOCK 3000 rpm
(Weld)
RUN
OR 3000 rpm
(Weld)
UNLOCK LOCK
Ref. ST-168 046
1 Engine Control Switch S2 Use control to change engine air-fuel mix. Use switch to select weld amperage range.
Use switch to start engine, select speed, To Start: pull out choke and turn Engine
and stop engine. In Run/Idle position, en- Control switch to Start position. Release For best arc starts, use lowest amper-
gine runs at power/idle rpm at no load, and switch and slowly push choke in when en- age range possible.
weld/power rpm under weld or 100 Hz auxil- gine starts. Do not crank engine while fly- 6 Fine Amperage Control R1
iary power receptacle load. In Run position, wheel is turning.
engine runs at weld rpm. Use control to select weld amperage within
To Stop: turn Engine Control switch to Off the range selected by the Ampere Ranges
2 Idle Lock Switch S1 position.
Use switch to lock engine at power/idle switch. Control may be adjusted while weld-
4 Remote Control Switch S4 ing. Scale is for reference only. Weld output
speed (see Table). In Unlock position, En-
gine Control switch and optional Remote Use switch to select front panel or remote would be 88 A DC with control settings as
Control switch determine engine speed. amperage control (see Section 3-2). shown (50% of 70 to 105 A).
3 Engine Choke Control 5 Ampere Ranges Switch S5 7 Engine Hour Meter HM

3-2. Remote Control (Optional)
Weld output terminals are
energized when Remote
Control switch S4 is in Pan-
1 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 A DC
Percentage Of Range = 50%
Max = 88 A DC (50% of 70 to 105)
Max (88 A DC)
Min (70 A DC)
Set Switch Set Range Set Percentage Adjust Remote Control

ST-140 092-B
3-3. Duty Cycle

Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
Exceeding duty cycle can
damage unit and void war-
ranty.
100% Duty Cycle at 225 Amperes AC
Continuous Welding
SB-115 570

3-4. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of the welding generator. Curves of
other settings fall between the
curves shown.
SB-115 529-A / SB-115 528-A

SECTION 4 – OPERATING AUXILIARY EQUIPMENT
4-1. 100 Hz Auxiliary Power Receptacle And Circuit Breaker

Do not operate 50/60 Hz or
60 Hz equipment from 100
Hz receptacle.
1 115 V 9 A 100 Hz AC Recep-
tacle RC4
Receptacle supplies single-phase
power at weld speed only. Total
output available is 1 kVA/kW.
2 Circuit Breaker CB3
CB3 protects receptacle from
2 overload. If CB3 opens, receptacle
does not work.
Ref. ST-168 046
4-2. AC Auxiliary Power Curve
SB-115 571

4-3. 60 Hz Auxiliary Power Receptacles And Circuit Breakers
For 60 Hz For 60 Hz
Auxiliary Power Auxiliary
While Welding Power Only
LOCK UNLOCK
RUN/IDLE RUN/IDLE
4
0 100 0 100
PANEL PANEL
ON ON
1 5 2 6 3 7 8
9
Ref. ST-168 046
If unit does not have GFCI receptacle Reset button pops out and the circuit 8 Circuit Breaker CB2
tacles, use GFCI-protected exten- opens to disconnect the faulty equipment.
sion cord. Check for damaged tools, cords, plugs, etc. CB1 and CB2 protect all the 60 Hz recep-
connected to the receptacle. Press button to tacles from overload. If CB1 or CB2 opens,
1 120 V 15 A AC Duplex Receptacle RC1 the 240 volt receptacle and one of the 120
reset receptacle and resume operation.
2 120 V 15 A AC Duplex Receptacle RC2 volt receptacles does not work. 120 volts
At least once a month, run engine at may still be present at the 240 volt recep-
3 240 V 30 A Twistlock Receptacle RC3
power/idle speed and press Test button tacle. Press button to reset breaker.
Receptacles supply 60 Hz single-phase to verify GFCI is working properly.
power at power/idle speed only. Maximum 9 Total Auxiliary Power Output
output from each duplex receptacle is is 2.5 5 Circuit Breaker CB5
Combined output of receptacles limited to
kVA/kW. Maximum output from twistlock re- 6 Circuit Breaker CB7 the 5 kVA/kW output of the generator:
ceptacle is 5 kVA/kW. For 60 Hz auxiliary CB5 protects RC1 and CB7 protects RC2
power, set controls as shown in table. from overload. If CB5 or CB7 opens, the re- EXAMPLE: If 10 A is drawn from a 120 V du-
4 120 V 15 A AC Duplex GFCI Recep- ceptacle does not work. Press button to re- plex receptacle, only 16 A is available at the
tacles GFCI1 And GFCI2 (Optional) set breaker. 240 V receptacle:
If a ground fault is detected, the GFCI recep- 7 Circuit Breaker CB1 (120 V x 10 A) + (240 V x 16 A) = 5.0 kVA/kW

SECTION 5 – THEORY OF OPERATION
1 Engine
Supplies force to turn revolving
fields.
2 Revolving Fields (Rotor)
Turn at 1860 rpm maximum for pow-
13 ♦
er/idle and 3000 rpm maximum for
weld. The speed and excitation cur- Remote Control
rent of the field coils determine volt- Switch S4
ages in stator windings.
Remote 14 Panel
3 Stator Windings
Supply power to exciter, auxiliary 12 ♦ 12♦
power, and weld circuits.
Capacitor Board Remote
4 Fuse F1 PC5 And Remote 14 Control Board
Receptacle RC1 PC3
Protects exciter excitation winding 11
from overload.
5 Integrated Rectifier SR2 Voltage
Regulator
Changes ac output of stator wind- Board PC2
ings to dc to supply excitation current 18
to the exciter revolving field.
6 Control Relay CR5 Fine
Amperage CR3
Energizes when voltage is present in Control R1
exciter stator to disconnect field
flashing circuit.
3
7 Idle Module PC1 And Idle Lock
Switch S1 Voltage 60 Hz Auxiliary
1 2 Regulator Power
PC1 and S1 control engine speed.
Without a signal from CT1, PC1 low- Revolving Stator Windings
ers engine speed to power/idle rpm. Engine Fields (Rotor)
100 Hz
8 Throttle Solenoid TS1 Exciter Auxiliary Weld
Increases engine speed to weld rpm Power
when energized. 5
8
9 Current Transformer CT1 4
Throttle Integrated
Senses output from either weld or Solenoid Rectifier SR2 Fuse
100 Hz auxiliary power windings, TS1 F1
and signals PC1 to increase to or
maintain weld rpm.
10 Control Relays CR2, CR3, CR4 6♦ 9
CR2 energizes at weld rpm to supply Control Current
power to throttle solenoid TS1. Relay Transformer
CR5 CT1
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 7 7 16
output.
11 Voltage Regulator Board PC2 Idle Module Idle Lock Circuit
And Transformer T1 PC1 Switch S1 Breaker
CB3
PC2 monitors 50/60 Hz auxiliary
power voltage through T1, and main-
tains proper output by adjusting field
current. 10 17
12 Capacitor Board PC5, Remote Control Relays 100 Hz
14 Receptacle RC1, Remote CR2, CR3, CR4 Auxiliary Power
Control Board PC3 Receptacle RC4
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
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 overload.
17 100 Hz Auxiliary Power Re-
ceptacle RC4
Provides connection point and
power for auxiliary equipment
while welding.
18 Fine Amperage Control R1
11
Adjusts amperage within range se-
CR4 lected by Ampere Ranges switch
Transformer S5.
T1
19 Ampere Ranges Switch S5
Selects coarse range of weld out-
put from weld stator.
14 15 20 Reactor AC-Z
Circuit 50/60 Hz Tapped reactor limits weld output
Breakers Auxiliary Power and provides coarse ranges.
CB1, CB2, Receptacles
CB5, CB7 RC1, RC2, RC3 21 Main Rectifier SR1
Changes ac output from weld
windings to dc.
22 Stabilizer DC-Z
19 Smooths out current to dc weld
output terminals.
Ampere
Ranges 23 HF Filter Board PC4
Switch S5 Protects unit from high frequency.
24 Positive (+) And Negative (–)
DC Weld Output Terminals
20 23 25 Provide dc weld output.
Reactor Electrode And 25 Electrode And Work AC Weld
AC-Z Work AC Weld Output Terminals
Output Terminals
Provide ac weld output.
21
HF Filter
Main Board
Rectifier PC4
SR1
AC Or DC Control Circuits
Weld Current Circuit

22 24
Positive (+) And Mechanical Coupling
Stabilizer Negative (–) DC
DC-Z Weld Output Magnetic Coupling
Terminals
♦ Optional

NOTES

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%. 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 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.
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.

B. 50 Or 60 Hz Auxiliary Power
Trouble Remedy
No auxiliary power output at recep- Run engine at power/idle speed.

tacles RC1, RC2, or RC3.
Reset circuit breakers CB1 and CB2. Effective with Serial No. KE629034, also reset circuit breakers
CB5 and CB7 (see Section 4-3).
Check receptacles RC1, RC2, RC3 for continuity and proper connections. Replace receptacle(s) if nec-
essary.
Check connections to terminal strip 1T.
Check coil voltage and connections of control relay CR4. Check continuity of coil and condition of con-
tacts. Replace CR4 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.
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.
Check integrated rectifier SR2, and 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 PC2 and connections, and replace if necessary (see Section 6-9).
C. 100 Hz Auxiliary Power
Trouble Remedy
No auxiliary power output at receptacle Run engine at weld speed.

RC4.
Reset circuit breaker CB3 (see Section 4-1).
Check receptacle RC4 for continuity and proper connections. Replace receptacle if necessary.
Disconnect leads 90, 91, 92, and 93 from stator. Check continuity between leads 90 and 91, and 92 and
93. Replace stator if necessary.

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- Check oil level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual
gine Control switch S2 returns to Run for location). S3 should close when engine is running.
position.
Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see engine
manual).
Engine stopped during normal opera- Check oil level (see Section 2-4). Check low oil pressure shutdown switch S3 (see engine parts manual
tion. for location). S3 should close when engine is running.
Battery discharges between uses. Make sure Engine Control switch S2 is placed in the Off position when engine is not in use (see Section
3-1).
Prior to Serial No. KA780044, check fuse F2 and replace if necessary.
Clean battery, terminals and posts with baking soda solution; rinse with clear water.
Periodically recharge battery (approximately every 3 months).
Check voltage regulator according to engine manual.
Replace battery.
Engine idles, but does not come up to Wait 10 seconds for throttle solenoid circuit breaker CB4 to reset (see Section 8-6).
weld speed.
Place Idle Lock switch S1 in Unlock position (see Section 3-1).
Check continuity and connections of current transformer CT1, and replace if necessary.
Check 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 throttle linkage for smooth, non-binding operation.
Unstable or sluggish engine speeds. Readjust throttle linkage if necessary.
Tune-up engine according to engine manual.

6-2. Troubleshooting Circuit Diagram For Welding Generator
Resistance Values Test Equipment Needed:

a) Tolerance – ±10% unless specified
b) Condition – 70°F (21°C); cold machine
(no warm-up)
c) Wiring Diagram – see Section 9
d) Stop engine before checking resistance
R1 29 ohms
R2 34 ohms
R3 35 ohms
R4 2 ohms
R5 2 ohms
R6 thru R17 Less than 1 ohm
R18 Pull: Less than 1 ohm Hold: 16.5 ohms
See Section
6-16 for R2 and
R4 adjustment
V14/R17
I1 I2
V15 R1 R2
V16/ V17/
R16 R15
R14 R13
V18
V11,
V12,
V13/R12
Throttle
control relay
CR2 energized
at weld rpm
Field current
control relay CR3
and auxiliary power
V19 R18 control relay CR4
energized at
See Section 6-5 power/idle rpm
for PC1 data

Amperage Readings
(no warm-up); no load
I1 3 amps dc
I2 1.8 amps dc (R1 at min.) Voltage Readings

3.1 amps dc (R1 at max.)
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)
V3 At RC3 at power/idle rpm:
244 volts ac ±5% (50 or 60 Hz)
R6 V6/R3
122 volts ac ±5% (50 or 60 Hz)
R7 V8/ V5
R5 V5 At RC1 at power/idle rpm:
122 volts ac ±5% (50 or 60 Hz)
V7/
R4 V6 AC input to transformer T1: 122 volts ac
(power/idle rpm), 0 volts ac (weld rpm)
V7 AC output to PC2: 21 volts ac ±5%
V8 AC output to PC2: 21 volts ac ±5%
V4
V9 AC output from Regulator Power
See Sections 6-7 Winding (power/idle rpm)
thru 6-9 for PC2 data 158 volts ac ±5%
V10/R8 R11 V9/R9 V3 V10 AC output from Weld Winding at
weld rpm: 65 volts ac (R1 at min.), 80
volts ac (R1 at max.) (Do not exceed 80
volts ac)
R10 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)
See Section 5 for 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:
See Section 6-4 for at least 120 volts ac (Do not exceed
132 volts ac)
waveforms A thru D
V18 Battery output whenever engine is
running: 14 volts dc.
V19 AC Alternator output:
SC-168 053-A

6-3. Troubleshooting Circuit Diagram For Welding Generator With Optional Remote Control
Resistance Values
a) Tolerance – ±10% unless specified Test Equipment Needed:

machine (no warm-up)
c) Wiring Diagram – see Section 9
d) Stop engine before checking
resistance
R1 29 ohms
R2 34 ohms
R3 35 ohms See Section 6-13
for PC5 data
R4 2 ohms
R5 2 ohms
R6 thru R17 Less than 1 ohm
See Section
6-11
for PC3 data
Field flashing V14/R17

disconnect relay CR5
See Section
6-16 for R2 and
I1 I2 R4 adjustment
V15
R1 R2
V16/ V17/
R16 R15
R14 R13
V11, V12,
V18 V13/R12
Throttle
control relay
CR2 energized
at weld rpm
Field current
control relay CR3
and auxiliary power
control relay CR4
energized at
V19 See Section 6-5 power/idle rpm
for PC1 data

Amperage Readings
(no warm-up); no load
I1 3 amps dc
I2 1.8 amps dc (R1 at min.) Voltage Readings

3.1 amps dc (R1 at max.)
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)
244 volts ac ±5% (50 or 60 Hz)
122 volts ac ±5% (50 or 60 Hz)
R6 V6/R3 122 volts ac ±5% (50 or 60 Hz)
V6 AC input to transformer T1: 122 volts ac
V8/ V5 (power/idle rpm), 0 volts ac (weld rpm)
R7
R5 V7 AC output to PC2: 21 volts ac ±5%
V7/ V8 AC output to PC2: 21 volts ac ±5%
R4
V9 AC output from Regulator Power
Winding (power/idle rpm)
158 volts ac ±5%
V4
V10 AC output from Weld Winding at
weld rpm: 65 volts ac (R1 at min.), 80
volts ac (R1 at max.) (Do not exceed 80
V3 volts ac)
V10/R8 R11 V9/R9 V11 At rated DC weld load: At least
See Sections 6-7 1 volts ac
thru 6-9 for PC2 data
V12 At weld rpm and 100 watt light bulb load
applied: 3 volts ac or greater
R10 V13 Idle Lock switch S1 in Lock:
0 volts ac at all times
V14 AC output from Exciter Winding
V15 At RC4 at weld speed: at least 120
volts ac (Do not exceed 132 volts ac)
at least 120 volts ac (Do not exceed
132 volts ac)
See Section 5 for at least 120 volts ac (Do not exceed
PC4 information 132 volts ac)
V2/C/D V1/A/B
V18 Battery output whenever engine is
running: 14 volts dc.
See Section 6-4 for V19 AC Alternator output:
waveforms A thru D 17 volts ac (power/idle rpm)
SC-168 054-A

6-4. Waveforms For Sections 6-2 And 6-3
2 ms 50 V 2 ms 10 V
gnd gnd
A. DC Open-Circuit Voltage, Ampere Ranges B. DC Weld Output, 25 Volts DC, 100 Am-
Switch S5 In Max Position peres, Ampere Range Switch S5 In 70-105
Position (Resistive Load)
5 ms 50 V 5 ms 20 V
gnd gnd
C. AC Open-Circuit Voltage, Ampere Ranges D. AC Weld Output, 25 Volts AC, 100 Amperes,
Switch S5 In Max Position Ampere Range Switch S5 In 70-105 Position
(Resistive Load)
Waveforms shown are for 60 Hertz models;

waveforms for 50 Hertz models are similar.
Test Equipment Needed:

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

6-6. Troubleshooting Flowcharts For Idle Control Board/Module PC1
Engine does not go to power/idle rpm Engine does not go to weld rpm with
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 Run/Idle position; Idle
switch S2 in Run/Idle position. Lock switch S1 in Unlock position.
Check connections
Check for internal NO to Engine Control
NO load such as
0 (zero) volts ac present? +12 volts dc present? switch S2 and
shorted diode in ground connection
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

0 (zero) volts dc present?
to Engine Control Control switch in Run/Idle 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
NO Replace idle
0 (zero) volts dc Minimum of 1 volt ac present? to current
present after 12 to 18 seconds? board/module
transformer CT1.
PC1
YES
YES
Connect meter (DC) between

Check throttle solenoid TS1 terminal C (+) and terminal E (–).
linkage.
NO Replace idle
+12 volts dc present? board/module
Reinstall cover. PC1
YES
Check circuit breaker CB4, throttle

solenoid TS1 connections and
linkage, and control relay CR2.
Disconnect 100 watt light bulb

and meter leads.
Reinstall cover.

Engine does not go to weld rpm with Control Relays CR3 and CR4 do not
Engine Control switch S2 in Run position. energize at idle rpm (See Section 5 for
CR3 and CR4 information)

Connect meter (DC) between terminal A (+) and F (–) prior to
terminals D (+) and E (–). Serial No. JH300534, or B (+) and
F (–) effective with Serial No.
JH300534.
Start engine. Place Engine

Control switch S2 in Run position.
Start engine. Place Engine
Control switch in Run position.
Prior to Serial No. JH300534,

move Weld/Power switch S1 to
Weld position. NO Replace idle
0 (zero) volts dc present? board/module
PC1
Check connections
NO to Engine Control YES
+12 volts dc present? switch S2 and
ground connection Place Engine Control switch S2
(lead 33).
YES in Run/Idle position.

terminals C (+) and E (–).
NO Replace idle
PC1
NO Replace idle YES
PC1
Check control relays
YES CR3 andCR4.
Check circuit breaker CB4, throttle

solenoid TS1 connections and
linkage, and control relay CR2.
Reinstall cover.
Reinstall cover.

6-7. Voltage Regulator Board PC2 Testing Information Prior To Serial No. KE604176
Be sure plugs are secure before
2 testing. See Section 6-8 for specif-
1
ic values during testing.
1 Voltage Regulator Board PC2
2 Terminals A Thru G
Ref. ST-800 698-A / SA-099 497-B
6-8. Voltage Regulator Board PC2 Test Point Values Prior To Serial No. KE604176
a) Tolerance – ±10% unless

specified
PC2 Voltage Readings
b) Reference – to circuit com-
mon (lead 33) unless noted
Receptacle Value
A Circuit common
B 18 volts ac input with respect to pin A
C 18 volts ac input with respect to pin A
D Circuit common
E 130 volts ac input with respect to terminal G at power/idle rpm
F 55 volts dc output with respect to terminal D at power/idle rpm
G 130 volts ac input with respect to terminal E at power/idle rpm

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 RC1
Ref. ST-800 698-A / SA-160 889-A
6-10. Voltage Regulator Board PC2 Test Point Values Effective With Serial No. KE604176

specified
Receptacle Pin Value

RC1 1 18 volts ac input with respect to pin 5
2 Not used
3 18 volts ac input with respect to pin 5
4 Circuit common
5 Circuit common
6 130 volts ac input with respect to pin 8 at power/idle rpm
7 Not used
8 130 volts ac input with respect to pin 6 at power/idle rpm
9 55 volts dc output with respect to pin 4 at power/idle rpm

6-11. Optional Remote Control Board PC3 Testing Information
1 Be sure plugs are secure before
1 Remote Control Board PC3
2 Receptacle RC1
Ref. ST-800 698-A / ST-115 941-L / SA-138 247
6-12. Optional Remote Control Board PC3 Test Point Values

specified
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.


6-13. Optional Remote Capacitor Board PC5 Testing Information Effective With Serial No.
KD346698
4 3 Be sure plugs are secure before
1 Capacitor Board PC5
2 Remote 14 Receptacle RC1
3 Receptacle RC2
4 Terminal K
Ref. ST-800 698-A / SA-156 026-C
6-14. Optional Remote Capacitor Board PC5 Test Point Values Effective With Serial No.
KD346698

specified
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)

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

1 Brush Holder Retaining Bar
2 Brush Holder Bracket
Remove brush holder bracket.
Keep hardware for reinstallation.
3 Brush Holder
4 Brush With Spring
5 Brush Holder Cap
Mark and disconnect leads at
caps, and remove brushes from
bracket.
Replace brushes if damaged, or if
brush is at or near minimum length.
6 Slip Rings
Inspect slip rings. Under normal
use, rings turn dark brown.
If slip rings are corroded or surface
is uneven, insulate brush leads,
start engine, and clean rings with a
commutator stone. Remove as
little material as possible. Stop 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
3
4
5/16 in. (8 mm)

Minimum Length
9/16 in. (14.3 mm)

New Length
Replace
Damaged Brushes
Tools Needed:
1/2 in
ST-800 698-A / Ref. ST-115 942-F / S-0233-A

B. Adjusting Brush Position
Stop engine.
After installing brushes, adjust
brush position as follows:
1 Brush Holder
2 Brass Sleeve
3 Brush
4 Slip Ring
Loosen brush holder bracket
mounting hardware. Move bracket
until brass sleeves are positioned
as shown. Tighten hardware.
Reinstall side panels and cover.
If operation is still not okay, have a
qualified machine shop turn and
polish slip rings.
Side View
3/32 in
(2.4 mm)
3 2 1
Correct Brush Position Incorrect Brush Position
Top View
Center brushes on slip
rings.
4 3 2 1
Correct Incorrect
Brush Position Brush Position
Tools Needed:
3/8, 1/2 in
Ref. ST-800 698-A / Ref. ST-800 677-B

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
1 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.
2
5 Resistor R2
5 Stop engine before adjust-
4 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.
2 Stop engine. Allow engine to cool,
and then complete pre-operational
3 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

SECTION 7 – DISASSEMBLY AND REASSEMBLY
7-1. Disassembly Of Unit
Use Section 6-1 to determine if
trouble is in rotor, stator, engine or
a combination of these compo-
nents.
Remove sheet metal panels from
unit. Disconnect negative (–) bat-
tery cable from battery. Remove
spark plugs. Mark and disconnect
all stator leads.
Do not damage rotor or sta-
tor during this procedure.
Use hoist and lifting strap to re-
move the engine/generator as-
sembly.
Tools Needed:
3/8, 7/16, 1/2, 9/16 in

ST-800 710-A

7-2. Disassembly Of Generator
Hardware may differ from that shown.
Torques:
Prior To Serial No. KD523655 Effective With Serial No. KD523655

A 15 ft lb (20 N.m) A 15 ft lb (20 N.m)
B 30 ft lb (41 N.m) B 20 ft lb (27 N.m)
C 25 ft lb (34 N.m) C 25 ft lb (34 N.m)
D 15 ft lb (20 N.m) D 20 ft lb (27 N.m) 5
E 15 ft lb (20 N.m) E 15 ft lb (20 N.m)
C
6
D
7
4 8
3 9
2
10
1
11
12
16
E 15
14 13
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
With engine properly supported with blocks, Reinstall engine and generator parts as
remove hardware securing stator to engine. 9 Ball Bearing needed (see torque table).
Remove generator parts as needed: 10 Retaining Ring Reconnect fuel line, choke cable, and base
11 Integrated Rectifier SR2 ground cable. Reinstall spark plugs, battery
1 Fan Guard and tray, panels, and cover.
2 O-Ring 12 Brush Holder Bracket
Use cable ties to secure leads in existing
3 Endbell 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.

SECTION 8 – MAINTENANCE
8-1. Routine Maintenance
Stop engine before maintaining.
See also Engine Manual and mainte-
Recycle engine
nance label. Service engine more often
fluids.
during severe conditions.
8 Hours
Check Fluid
Wipe Up
Levels.
Spills
OIL See Section 2-4
Full
20 Hours
Check And
Clean Spark
Arrestor Screen
25 Hours
Clean And
Check Air
Cleaner
50 Hours
Clean And
Tighten Weld
Terminals
100 Hours
Change Oil. See Change Oil Filter. See
Section 8-4 And Section 8-4 And
Maintenance Maintenance Label
Label
Clean Cooling Clean And

System, Tighten
See Engine Battery
Manual Connections
200 Hours
Replace
Check Replace
Fuel Filter.
Valve Unreadable
See Section
Clearance Labels
8-4.
500 Hours
Repair Or Replace Check

Cracked Cables Spark
Plugs
1000 Hours
OR Blow Out Or Vacuum Inside.
During Heavy Service,
Clean Monthly

8-2. Maintenance Label
ONAN P218 GAS ENGINE

See Engine Manual for complete engine care. Give engine
Specification and Serial Number when ordering parts.
To Drain Oil: °C °F
+100
Push And +30
Check Turn CCW
30
+20
daily.
1/2 in. ID Hose +10
+40
Pull 0
10W
Recommended Oil . . . API Service Classification -10
SF, SG, SF/CC, SG/CE -20 0
5W-30
Oil & Filter Change . . . . . . . . . . -30
dirty conditions . . . 25 hours or less
normal conditions . 100 hours
Oil Filter . . . . . . . . . . . . MILLER 065 251, Onan 122-0645
Oil Capacity . . . . . . . . 1.5 qt (1.4 L) or 1.75 qt (1.6 L) with filter change
Fuel Grade . . . . . . . . . Regular or Unleaded

Fuel Filter . . . . . . . . . . MILLER 066 113, Onan 149-2206-01,
Fram G10E1
Gasoline
Air Filter Service . . . . 100 hours or less – see Owner’s Manual
Air Filter Element . . . . MILLER 064 617, Onan 140-2522
Air Filter Wrapper . . . . MILLER 065 653, Onan 140-1496
12 Volt Battery . . . . . . . . . . . . . . . . . . . . . . . . BCI Group 58

+
Cranking Performance at 0°F (-18°C) . . . . 430 Amps min.
Engine RPM – No Load

Valve Clearance – Cold
Power . . . 1650 (50 Hz)
In. . . . 0.005 in (0.13 mm)
1860 (60 Hz)
Ex. . . 0.013 in (0.33 mm)
Weld . . . . . 3000
Spark Plug Gap . . . . . 0.025 in. (0.6 mm)

Spark Plug . . . . . . . . . Champion RS17YX Preferred or
RS14YC
Use only resistor spark plugs and wires.
Spark Arrestor Inspection And Service . 20 operating hours -

see Owner’s Manual
Optional S-176 891

8-3. Servicing Air Cleaner
Do not run engine without
air cleaner or with dirty ele-
ment.
1
Stop engine.
1 Precleaner
2 Wash precleaner with soap and

water solution. Allow precleaner to
air dry completely.
Spread 1 tablespoon SAE 30 oil
evenly into precleaner. Squeeze
out excess oil.
2 Element
Replace element if dirty or oily.
oil
aircleaner3 1/96 – ST-156 852 / S-0759

8-4. Changing Engine Oil, Oil Filter, And Fuel Filter
1 Oil Drain Valve
2 1/2 ID x 12 in Hose
3 Oil 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).
Full 4 Fuel Filter
5 Fuel Line
Replace line if cracked or worn.
Install new filter. Wipe up any
spilled fuel.
Start engine, and check for fuel
leaks.
Stop engine, tighten connections
as necessary, and wipe up fuel.
Tools Needed:
ST-140 091-E / ST-144 840-C Ref. ST-168 046 / ST-800 395 / S-0842

8-5. Adjusting Engine Speed
After tuning engine, check engine
speeds with a tachometer. See
table for proper no load speeds. If
necessary, adjust speeds as fol-
lows:
Start engine, and place Engine
Control switch in Run/Idle position.
Turn Fine Amperage control to
100.
1860 rpm 1 Carburetor
(Power/Idle) 2 Throttle Solenoid
2 3000 rpm Power/Idle Speed Adjustment
(Weld)
3 Power/Idle 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
Rear View position.
6 Lock Nut
Loosen nut.
1 7 Hex Swivel
Turn swivel until engine runs at
weld speed. Tighten lock nut.
8 Weld Speed Governor Spring
9 Power/Idle Speed Governor
Spring
If a spring becomes loose or dis-
connected, reattach as shown.
5 9
4 3
8 6 7
Top View
Tools Needed:
3/8 in,
8, 11 mm ST-116 049-C

8-6. Overload Protection
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.
2 Replace open fuse and reinstall
panel before operating unit.
If F1 continues to open, check inte-
grated rectifier SR2 and rotor.
Tools Needed:
3/8 in
ST-152 264-A
8-7. Inspecting And Cleaning Optional Spark Arrestor

1 Spark Arrestor Screen
Clean and inspect screen. Re-
place spark arrestor if screen wires
are broken or missing.
Tools Needed:
1/4 in
ST-140 091-E / ST-801 206 / Ref. ST-168 046

SECTION 9 – ELECTRICAL DIAGRAMS
The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact factory for actual circuit, if needed.
The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:
1 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.
Circuit Wiring Main Reason

Model Serial Or Style Number
Diagram Diagram For Change
Miller Legend Without Re- JH242114 thru JH300533 SC-114 477-A D-117 651♦♦
mote Control
JH300534 thru JJ420470 C-117 626-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- JH242114 thru JH300533 SC-115 947-A

mote Control
JH300534 thru JJ420470 C-118 207-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 JH242114 thru JH300533 SB-113 710
Circuit Board PC2 JH242114 thru KE604175 B-049 506-C♦♦
KE604176 and following SB-160 891
Circuit Board PC3♦ JH242114 thru KA840709 B-115 891-A♦♦
KA840710 and following SB-136 249
Circuit Board PC4 KD346698 and following SA-148 024-A
Circuit Board PC5♦ KD346698 and following SB-156 027
♦ Optional ♦♦ Not included in this manual

SC-114 477-A
Figure 9-1. Circuit Diagram For Miller Legend Without Remote Control
Effective With Serial No. JH242114 Thru JH300533

SC-168 053-A
Figure 9-2. Circuit Diagram For Miller Legend Without Remote Control
Effective With Serial No. KE629034 And Following

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

SD-168 051-B

SC-115 947-A
Figure 9-4. Circuit Diagram For Miller Legend With Remote Control

SC-168 054-A
Figure 9-5. Circuit Diagram For Miller Legend With Remote Control

SB-113 710
Figure 9-6. Circuit Diagram For Idle Control Board PC1

SB-160 891
Figure 9-7. Circuit Diagram For Voltage Regulator Board PC2


OUTPUT
POSITIVE
SUPPLY+
SB-136 249
Figure 9-8. Circuit Diagram For Optional Remote Control Board PC3
Effective With Serial No. KA840710 And Following
SB-148 024-A
Figure 9-9. Circuit Diagram For HF Filter Board PC4

Effective With Serial No. KD346698 And Following

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

7
Figure 10-5
5
TM-428 Page 52
Figure 10-6 2
3 4
1
20 19
21
22
23
24 25
26

44
Figure 10-3 8 18
47 9 12 17
13 15 16
43 45 46 14
10
11 27
42 48
49 28
34 29
50 Figure 10-2
33
41 30
40 51
31
32
39
38 35
36
37
Figure 10-1. Main Assembly
Miller Legend
Item Dia. Part
No. Mkgs. No. Description Quantity
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 PANEL, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 113 303 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 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 . . . . . SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Item Dia. Part
Figure 10-1. Main Assembly (Continued)
. . . 27 . . . . . . . . . . . . . . 107 308 . . . HOLD DOWN, bat (Prior to KB113874) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . . . . . . . . . 146 697 . . . HOLD DOWN, bat (Eff w/KB113874 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, (Eff w/KA780148 thru KB113873) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . 146 710 . . . BASE, (Eff w/KB113874 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 TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Item Dia. Part
Figure 10-2. Generator (Figure 10-1 Item 34)
. . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . 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 . . ROTOR ASSEMBLY, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . 017 624 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 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
. . . 15 . . . . . . . . . . . 007 250 . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 047 878 . . BAR, retaining brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . 161 306 . . CAP, brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . *126 984 . . BRUSH w/SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 19 . . . . . . . . . . . 005 614 . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11 9
6 12 10
13
1 2 3 4
14
19 15
18
16
17
ST-115 942-F
Figure 10-2. Generator
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.

Item Dia. Part
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 250VAC (Eff 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
. . . 3 . . . . . . . . . . . . . . 170 554 . . . PANEL, front (Eff w/KF790320 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 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
Figure 10-4
2 3
5 6 7
8
9 10
35
34
11 14 15
33 12
13
32
31
30
29 16
28
27
18
17
26
25
20
24
21
23
21 19
22
ST-115 943-J
Figure 10-3. Panel, Front w/Components


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

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

Item Part
No. No. Description Quantity
005 563 Figure 10-4. Switch, Selector (Figure 10-3 Item 4)
... 1 ........ 005 562 .. BRACKET, mtg-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 ........ 005 561 .. SHAFT, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 ........ 005 564 .. INSULATOR, screw switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 ........ 605 276 .. SCREW, cap stl hex hd .250-20 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 ........ 005 559 .. CONTACT BOARD, movable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ........ 005 560 .. CONTACT, switch movable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 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
... 12 . . . . . . . . 005 557 .. BUS BAR, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . 005 558 .. SPRING, selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10
7 11
6
4
12
3
13
ST-097 264-A
Figure 10-4. Switch, Selector

Item Dia. Part
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
. . . 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 . . . CONNECTOR & SOCKETS, (Eff 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
. . . 12 . . . . . . . . . . . . . . 038 620 . . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . D6 . . . . . 117 566 . . . DIODE, rect 6A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1
Figure 10-7
4
12
11
10
7
5
9 6
8 ST-114 309-B
Figure 10-5. Control Panel, w/Components


Item Dia. Part
+042 132 Figure 10-6. Remote Control, Option (Figure 10-1 Item 1)
+042 383
. . . 1 . . . . PC3 . . . . 136 246 . . . CIRCUIT CARD ASSEMBLY, remote control . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .............. 110 375 . . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 3 .............. 116 086 . . . BRACKET, mtg remote control (Prior to JK563388) . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 125 873 . . . BRACKET, mtg remote control (Eff w/JK563388) . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . CR5 . . . . 052 603 . . . RELAY, encl 110VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 007 532 . . . CLAMP, capacitor 1.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . C5 . . . . . 059 887 . . . CAPACITOR, polyp met film 10uf 220V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . 2T . . . . . 116 005 . . . BLOCK, term 10A 7P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 108 023 . . . LINK, jumper term blk 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . PLG6 . . . . 115 091 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 113 746 . . . . . TERMINAL, female 1skt 18-24W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4
6 5
SB-116 028
Figure 10-6. Remote Control, Option
+See Figure 10-3 for additional parts not listed


Dia. Part
Mkgs. No. Description Quantity
PC2 160 888 Figure 10-7. Circuit Card, Voltage Regulator (Figure 10-5 Item 4)
. . . . . . A50 . . . . . . . 165 411 ... IC, linear 2904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . C1 . . . . . . 003 530 ... CAPACITOR, cer mono 1uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C50 . . . . . . . 119 199 ... CAPACITOR, polye met film 1uf 50V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C51 . . . . . . 053 992 ... CAPACITOR, cer disc .001uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C52 . . . . . . 000 348 ... CAPACITOR, tantlm .47uf 35V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C53 . . . . . . 005 023 ... CAPACITOR, tantlm 2.2uf 20V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C54 . . . . . . 072 935 ... CAPACITOR, elctlt 33uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C55 . . . . . . 137 463 ... CAPACITOR, polye met film .22uf 100VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C56 . . . . . . . 072 113 ... CAPACITOR, tantlm 4.7uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . C57 . . . . . . 028 292 ... CAPACITOR, cer disc .005uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . D50 . . . . . . 028 351 ... DIODE, sig 200mA 75V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . D51 . . . . . . 049 641 ... DIODE, zener 27V 1W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . D52-54 . . . . 026 202 ... DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . D55-58 . . . . 070 250 ... DIODE, rect 3A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . D59 . . . . . . 030 529 ... DIODE, rect 22A 600V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . Q50 . . . . . 039 355 ... TRANSISTOR, ujt 15mA 40V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . Q51,52 . . . . 037 200 ... TRANSISTOR, NPN 200mA 40V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . Q53,54 . . . . 049 642 ... THYRISTOR, SCR 8A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . R50 . . . . . . 094 447 ... RESISTOR, MF .25W 681K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . R51 . . . . . . 044 789 ... RESISTOR, MF .25W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . R52 . . . . . . 035 829 ... RESISTOR, MF .25W 1.5K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . R53,54,65 . . . 072 559 ... RESISTOR, MF .25W 22.1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . R55 . . . . . . . 115 530 ... RESISTOR, MF .25W 2.67K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . R56,64 . . . . 000 885 ... RESISTOR, MF .25W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . R57,62 . . . . 028 285 ... RESISTOR, C .5W 100 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . 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
. . . . . . R69 . . . . . . 049 439 ... RESISTOR, C 2W 47K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . R70 . . . . . . 074 099 ... RESISTOR, C 1W 150 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . R71 . . . . . . 030 707 ... RESISTOR, C 1W 47 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . 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


Technical Manual TM-428

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What is the purpose of this technical manual?

What is the purpose of this technical manual?

What safety precautions should be taken when servicing the equipment?

What safety precautions should be taken when servicing the equipment?

February 1996 Form: TM-428

Effective With Serial No. JH242114

Weld Rated Maximum

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WHO DO I CONTACT FOR HELP?

Always provide Model Name and Serial or Style Number

OM-428N 1/96 – SPM-428C 6/94

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2-1. Installing Welding Generator

Movement Airflow Location

Do Not Lift Unit From End 18 in

Grounding 1 Generator Base

2-2. Dimensions, Weights, And Operating Angles

Depth 45 in (1143 mm)

B A 16-1/2 in (419 mm)

Engine End Ship 600 lb (272 kg)

Miller Legend TM-428 Page 3

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2-4. Engine Prestart Checks

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

TM-428 Page 4 Miller Legend

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Connect (–) cable last.

2-6. Connecting To Weld Output Terminals

Miller Legend TM-428 Page 5

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150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

Welding 10 – 60% 60 – 100%

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

2-8. Remote 14 Receptacle RC1 Information

Socket* Socket Information

A Contact closure to B completes 15 volts dc contactor control

C +4.5 volts dc output to remote control.

A J D Remote control circuit common.

*The remaining sockets are not used.

TM-428 Page 6 Miller Legend

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Ref. ST-168 046

Miller Legend TM-428 Page 7

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Max (88 A DC)

Min (70 A DC)

Set Switch Set Range Set Percentage Adjust Remote Control

3-3. Duty Cycle

100% Duty Cycle at 225 Amperes AC

TM-428 Page 8 Miller Legend

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

Miller Legend TM-428 Page 9

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